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Cladding

Bridges

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Stairs

Restorations

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Panel Fixation Solutions

Ductal Textures

LEED

If you have a project you would like to discuss contact

Lafarge10655 Southport Rd. S.W. • #1200Calgary,ABT2W 4Y1 • CanadaPhone: 403-225-5456 •Toll free: [email protected]

www.imagineductal.com

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Newsletter Ductal n°2



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Ductal® is an Ultra-High Performance, Fiber Reinforced Concrete

technology that offers superior strength (compressive strengths up to

30,000 psi and flexural strengths up to 6,000 psi), durability, ductility

and aesthetic design flexibility. By utilizing its unique combination of

properties, designers can create thinner sections and longer spans that

are lighter, more graceful and innovative in geometry and form, while

providing improved durability and impermeability against corrosion,

abrasion and impact. Many economies gained are a result of

What is Ductal?What is Ductal?

abrasion and impact. Many economies gained are a result of

engineering new solutions for old problems. The strength of Ductal®

allows for solutions to be designed with smaller elements, without the

use of passive reinforcing steel and, in most applications, without

prestressed or post-tensioned reinforcement. Advantages may

include: reduced global construction costs, formworks, labor and

maintenance; relating to improved site construction safety, speed of

construction and extended usage life.

Ductal® Properties

StrengthStrength

Ductility

Durability

Aesthetics

�Compressive Strengthup to 30,000 psi (200 MPA)

�Flexural Strengthup to 6,000 psi (40 MPA)

�Direct Tension up to 1,450 psi (10 MPA)

�Ductility

InnovationInnovation

�DuctilityGreater capacity to deform and support flexural and tensile loads, even after initial cracking.

�Abrasion ResistanceSimilar to natural rock

�ImpermeabilityAlmost no carbonation or penetration of chlorides.

Steel

Pre-stressedReinforcedConcrete

Beams of Equal Load Carrying Capacity

UltraUltra--High StrengthHigh Strength

Mass (weight) of Beamskg/lineal meter 140 112 467 530lbs/lineal ft. 94 75 313 355

25

30

35

40

45

50

Eq

uiv

ale

nt

Str

es

s (M

Pa

) Ductal

HPC 80

Ductal®

HPC

DuctilityDuctility

0

5

10

15

20

25

0.0 0.5 1.0 1.5 2.0

Deflection (mm)

Eq

uiv

ale

nt

Str

es

s (M

Pa

)

2,000 lb car on a

1 ¼ -inch sheet of Ductal®

(31.75 mm)

Treat Island, Maine, USA

DurabilityDurability

U.S Army Corp. of Engineers

Long-term Exposure Site

Three samples of Ductal®

installed in 1996

EXPOSURE [2006]•1000 freeze/thaw cycles,

•7500 wet/dry cycles in

saturated sea water

•High abrasion from waves

and ice

Ductal®

replicates texture, form

and shape.

Finished products can be

created in

a range

of colors and provide

new freedoms in

AestheticsAesthetics

new freedoms in

architecture.

Who is Lafarge?

World leader in building materials, Lafarge extracts

resources from the heart of the earth to make materials to

bring to the heart of life. Present in 79 countries, the Group

responds to the world’s demand for housing and

infrastructure. Lafarge is driven by the needs of its

customers, shareholders, local communities and architects.

The Group creates high value-added solutions which

1

The Group creates high value-added solutions which

encourage creativity whilst leaving a lighter trace on the

world.

Architectural Solutions

1

Villa Villa NavarraNavarra Art Art GalleryGallery

Le Muy, France

Designer: Rudy Ricciotti

Built: 2007

Dimensions: 10m x 2m x 3cm

cantilevers 8m (26 ft)

Fabricator: Bonna Sabla

2

Hotel Rialto Hotel Rialto RestorationRestoration

Victoria, Canada

Designer: Nolan Mayrhofer

Built: 2008

Fabricator: Szolyd Development Corp.

3

ShawnessyShawnessy LRT StationLRT Station

Calgary, Canada

Designer: Stantec

Built: 2004

Dimensions: 3m x 5m x 20mm

Fabricator: Lafarge North America

4

Bus ShelterBus Shelter

Tucson,USA

Designer: Line and Space, LLC

Built: 2001


5

Cladding

6

Jumping TroutJumping Trout

Calgary, Canada

Designer: Violet Costello & Bob Thomasson

Built: 2007

Dimensions: 14 feet long, 1¼″ at center, tapering to ¾″ at edges


7

Musée d’art brut Musée d’art brut

Villeneuve d’Asque, France

Designer: Manuelle Gautrand

Built: 2007

Dimensions: 185 m2

Fabricator: Betsinor and Jousselin

8

Maison de quartierMaison de quartier

Sedan, France

Designer: Philippe Gibert

Built: 2008

Dimensions: 330 m2

Fabricator: Betsinor

9

Sound Attenuation Panel, Train StationSound Attenuation Panel, Train Station

Monaco

Designer: Jean-François Picardat

Built: 1999

Dimensions: 1600 m2

Fabricator: Bouygues

10

Kindergarten BellevilleKindergarten Belleville

Belleville, France

Designer: Bruno Rollet

Built: 2007

Fabricator: Jousselin

11

RATP Bus TerminalRATP Bus Terminal

Thiais, France

Designer: Dominique Marrec

Built: 2008

Dimensions: 1300 m2


12

Rhodia Headquarters Rhodia Headquarters

Aubervilliers, France

Built: 2000

Dimensions: .2 cm thick panels, 1.7 X 2.5 M

Fabricator: EPI

13

ZAC ZAC ApartmentsApartments

Paris, France

Designer: Badia Berger

Built: 2007

Dimensions: 2.5m x 6.5m x 3cm

(7 -9 cm at connectors)

Fabricator: Betsinor and Jousselin

14

Under Armour StoreUnder Armour Store

Aurora, USA

Designer/Fabricator: Bill Gockeler

Built: 2008

Dimensions: 4′ x 8′ x ½″ panels

15

Bridges

16

Glenmore / Glenmore / LegsbyLegsby Pedestrian BridgePedestrian Bridge

Calgary, Canada

Designer: Cohos Evamy

Built: 2007

Dimensions: Ductal® girder 33.6m long,

1.1m deep at mid-span, 3.6m wide deck


17

Sakata Mirai BridgeSakata Mirai Bridge

Sakata, Japan

Designer: Taisei Corporation

Built: 2002

Dimensions: Top slab: 5cm,

Web: 8cm x 50.2 m long

Fabricator: Taiheiyo Cement Corp. +

Maeta Concrete Ind.

18

The Footbridge of PeaceThe Footbridge of Peace

Seoul, Korea

Designer: Rudy Ricciotti

Built: 2002

Dimensions: Central Ductal ® arch: 120m long

4.30m wide, thickness 3cm

Fabricator: VSL Korea

19

Furniture + Decor

20

Yves Saint Laurent BoutiqueYves Saint Laurent Boutique

Houston, USA

Designers:

Chair: Alain Moatti & Henri Rivière

Table, Bench, Display: David Udkom

Built: 2008

Fabricator: M3Beton

21

United Nations United Nations PlazaPlaza

Geneva, Switzerland

Designer: Christian Drevet

Fabricator: Jousselin

22

8.0 Chair8.0 Chair

Designer: Omer Arbel

Fabricator: Groupe Tremca

23

H2O ChairH2O Chair

Designer/Fabricator: JJ.Hubert, H2O architecture

24

SwingSwing

Designer /Fabricator: Francesco Passaniti

Compact Concrete

25

Sol® et Bouquet®Sol® et Bouquet®

Designer/Fabricator: Diego Fortunato

26

PlantersPlanters

Designer/Fabricator: Solus Decor

27

UrbanUrban FurnitureFurniture

Designer: Gigi Rossi

Fabricator: Il Cantiere

28

Contemporary SurfacesContemporary Surfaces

Designer: Leo Chester


29

Gigi Rossi

Fireplace SurroundsFireplace Surrounds

30 Solus Decor Solus Decor

LampsLamps

31

Somnuk Tao, Ora-ïto, Philippe Stark

Six Pieds sur Terre

Designer/Fabricator: Solus Decor

Fire Fire PitPit

32

Stairs

33

Floating StairFloating Stair

Houston, USA

Designer: Walter P. Moore / Mark Wagonner

Built: 2007


34

Spiral StairSpiral Stair

Paris, France

Designer/Fabricator: Cogitech design

35

Restorations

36

HotelHotel RialtoRialto

Victoria, Canada

Designer: Nolan Mayrhofer

Restored: 2008


37

Campanile Palais de JusticeCampanile Palais de Justice

Laval, France

Restored: 2005

Fabricator: Gilles Deniau

38

Havas Group Headquarters Havas Group Headquarters

Suresnes, France

Restored: 2003


39

Clichy Clichy SwimmingSwimming PoolPool

Clichy, France

Designer: ENIA

Restored: 2006


40

Lafarge North America Inc.

Ph. 1-866-2 DUCTAL or (403) 271-9110 Fax. (403) 278-7420

Email: [email protected] www.imagineductal.com

Testimonials

Bill Gockeler President Artisans in Concrete (Precast Inc. Article) – May 2009

I see UHPC (Ductal®) being a huge benefit for decorative concrete applications. Many of our design challenges with traditional concrete stem from its weight. For example, the large-format floor tiles we manufacture using our high-strength concrete are 1 inch thick (25.4 mm). With a 4-by-4-foot tile, this equates to a weight of approximately 200 pounds (90 kg) per tile, which is very difficult and expensive to install. Using UHPC, we can produce the same size tile weighing only 50 pounds (22.7 kg). Steve Barber Senior Heritage Planner City of Victoria (Hotel Rialto) - April 2009

Barber says because of the pilot aspect of the project the city had to be convinced that the renovation would be economically viable and would have a positive impact on the area around the hotel. Ultimately the City council enthusiastically embraced the project. William F. Baker partner SOM (AIA Center for Architecture NY exhibition) – March 2009

Future architecture will utilize materials that look familiar but are quite different. There will be concretes that may look like what you see in the sidewalk but will be quite different. They will be so much stronger and stiffer than traditional concretes that they become virtually a new material. An example of the future is Ductal®, an ultra high performance concrete that is included in the New York AIA Exhibition.

Akihiko Kodama Manager of Taiheiyo Cement Corp. (Haneda Airport Tokyo) - March 2009

Costs are significantly reduced for this unprecedented structure due to the durability and surprisingly lightweight design of the Ductal® slabs. Given the characteristics of the material, the weight of the slabs can be reduced, as can the cost of the steel casing and the piles. Rudy Ricciotti Project Architect (Pont du Diable Footbridge) - March 2009

The difference between utopia and action is this reality of implementation. The paradox between high-level technological assertion and physical disappearance assumes its full value and meaning in an exceptional landscape. It means believing in the material “Ductal®” and what we can get it to say. And asking one’s self whether the structure’s mathematical reasoning belongs to the person reasoning or whether it is already part of the material itself? Philippe Gibert Project Architect (Sedan Cultural Center) – July 2008

Although some perforations reached 6.5 cm in diameter, with the constant performance of the material we were able to produce panels of 2m x 4.5m, but only 5 cm thick, to cover the 330m2 of façade and respect all the requirements of weight, transparency and protection expressed by the project owner. Beaux Arts Magazine – May 2008

A great many new architectural projects will soon grow up out of the ground as if pulled out by designers with a love for twists, turns and torsions. Only greater computing power and the constant innovations in concrete products such as Ductal® let these buildings grow upwards and outwards.


Ph. 1-866-2 DUCTAL or (403) 271-9110 Fax. (403) 278-7420


Nolan Mayrhofer Owner/Designer/Precaster Szolyd Development Corp – February 2008

Ductal® offers an amazing addition to the materials we work with. It allows us to create products that were previously inconceivable. As we explore the flexibility that Ductal® allows, we notice a new level of creativity in the projects our clients bring to us. We know we have only begun to scratch the surface of its potential and realize that its applications are limited only by our imaginations. Sylvain Quidant Director Cogitech Engineering – December 2007

We are just beginning to exploit Ductal’s® potential.

Rudy Ricciotti Project Architect (Villa Navarra) – December 2007

Ductal® makes it possible to dispense with the framework leaving the designers completely free to consider new shapes.

Emmanuel Combarel Project Architect (Tomi Ungerer Center National de l’illustration) – Sep. 2007

Ductal® has therefore made it possible to design an extremely thin footpath which is finally what gives us the strange impression of seeing people in a state of levitation as it disappears into the vegetation. Gerald Carson Project Engineer Cohos Evamy (Glenmore / Legsby footbridge) – April 2007

Because of the slenderness and strength offered by Ductal®, we were able to work with a wide selection of aesthetic possibilities that would never have been possible with conventional concrete.

Luigi Rossi Designer for Cantiere (Standard furniture pieces) – April 2007

This material has become a source of inspiration for a range of decorative wall panels, interior and outdoor lamps, mantelpiece cornices, furniture… The range of possibilities opened by the strength, utilization flexibility and available finish range is particularly vast.

Alberta Construction Magazine – November 2006

By meeting the requirements for durability and lightness, Ductal® has opened up the way for experimentation. Benjamin Graybeal FHWA (Wapello County Iowa bridge girders) – March 2006

One of the series of tests enabled us, for example, to show that Ductal® involves the use of far fewer materials, thereby enabling us to build sleeker bridges, comparable to steel bridges: which are lighter and stronger at the same time. Manuelle Gautrand Project Architect (Lille Museum of Modern Art) – July 2005

What we found most exciting was the possibility to create a lattice out of concrete and achieve a smooth, matte finish – light, very sober and refined. Technically, Ductal® was perfect for sculpting on extremely thin concrete plates almost three times thinner than conventional concrete. Not only did this solve the weight problem, but it makes the hanging work easy and they can be placed in front of picture windows.


Ph. 1-866-2 DUCTAL or (403) 271-9110 Fax. (403) 278-7420


Focus Magazine – November 2004

According to Benjamin Graybeal of FHWA, before the development of Ductal® the idea of building a bridge that could last over a century was unthinkable. He suggests that today’s bridges, because of Ductal®, last far longer than the actual roads. Enzo Vicenzino Project Architect (Shawnessy LRT) – October 2004

Ductal® provided the ability to achieve the free-flowing form design of the canopies.

Ductal® Panel

Fixation SystemsFixation Systems

RATP Bus TerminalThiais, France

Dimensions: 1300 m2 (13,988 ft2)

This system used in France, ensures

that each panel is aligned perfectly

with the next, by allowing tolerances

to be absorbed at the structure.

1. Stainless steel bolt

2. Slip Washer (for tolerance adjustment)

3. Stainless steel brackets

4. Welded metal bridge bar

5. Keil bolting system on Ductal® panels

ZAC apartments

Paris, France

Dimensions: 2.5m x 6.5m x 3cm

(8.2 ft x 21.3 ft x 1 in)

Bellville Kindergarten

Created by Hilit, this simply supported

system allows the entire panel to rest

on two points at its base. Hidden in

two trough cut outs.

Bellville Kindergarten

Bellville, France

Dimensions : 3cm (1 in) various size panels

This system utilizes a single, and in

some larger panel cases two Keil

stainless steel bolts affixed directly

through the front of the panel.

Rhodia headquartersAubervilliers, France

Dimensions: .2 cm thick panels, 1.7 X 2.5M

(.078 in x 5.5 ft x 8.2 ft)This system is typically used for

affixing stone panels. In order to have

good shear/punching resistance for

the Ductal ® panel, the thickness of

the panel was increased to 33 mm, at

the insertion point.

Textures

41

With chameleon-like qualities, Ductal ®

replicates texture, form and shape with high

precision and can be produced in a range of

long-lasting colors. Liquid or powder color

pigments may be added and finished

surfaces may be further protected from

42

surfaces may be further protected from

fading, blotching and graffiti, with the use of

clear-coat sealants.

Your imagination is the limit.

TexturesTextures

43

TexturesTextures

44

TexturesTextures

45

Ductal® is an ultra-high performance, composite material that provides strength, ductility, durability and aesthetics. This unique combination of superior properties facilitates the ability to create innovative designs with new shapes that are thinner, lighter and more graceful.

What is Ductal® made of ? Components: • Cement • Silica Fume • Quartz • Sand • Fibers (metallic or poly-vinyl alcohol) • Superplasticizer • Mineral Fillers • Water

The following is a list of LEED® credits that some Ductal® projects may contribute to, depending on the application. For more detailed LEED® credit information about a specific project, please contact a Ductal® representative.

LEED® credit information for Ductal® solutions

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LEED® for US + Ca

SS Credit 3 Brownfield Development Brownfield remediation through contamination containment using Ductal® slabs.SS Credit 5.1 Reduced Site Disturbance Precast pieces require less set up and deployment space as well as being a much faster erection process, there by reducing total construction time and site disturbanceSS Credit 6.1 & 6.2 Storm Water Management Can be used in landscaping as part of a filtration system, storm water retention system, or in a “Green Roof” Design.SS Credit 7.1 Heat Island Effect Non-Roof Mix designs with white cement contain an SRI a reflectance of .7 and emittance value of .9.

WE Credit 2 Innovative Wastewater Ductal® wastewater treatment troughs have Technologies high abrasion resistance.

EQ Credit 7.1 Thermal Comfort Ductal® thermal characteristics can assist with the building envelope thermal efficiency.

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Kelly Henry LEED® AP.

Lafarge1200, 10655 Southport Road S.W.Calgary, Alberta, Canada T2W 4Y1Email: [email protected] • Tel: 403-225-5456• Toll free: 1-866-238-2825 • www.imagineductal.com

enerGY & atmosphere

sustainaBle site selection

Water efficiencY

materials & resources

indoor enVironmental QualitY

EA Prerequisite 2 Minimum Energy Ductal® has the same natural thermal insulative Performance values as concrete. Panels used in a building envelope can be modeled to show these characteristics and contribute to the overall energy performance simulation.

MR Credit 1.1 -1.3 Building Reuse The high durability and high matrix density allows for a longer structural lifespan for elements constructed with Ductal®. Building reuse credits may be gained if working on a building that has already utilized Ductal® in the past. MR Credit 8* Durable Building *This credit exists in the Canadian LEED® program. Ductal® is a highly durable and abrasion resistant material, exceeding typical concrete life span calculations by several years. MR Credit 2.1 - 2.2 Construction Waste Should precast pieces in reuse / referbish Management projects not meet the specification of the building components, the pieces can be recycled as part of the waste management protocol set up for the project.MR Credit 4.1 Recycled Content Metal fibers and silica fume constitute more than 10% of the raw materials in the Ductal® premix. Calculations for recycled content contribution to the total project can be provided upon request.

Amajor part of the renovation of Orly’s P0 parking

lot concerns the cladding on the walls along the

parking lot entrances and on the elevators by which

pedestrians access concourses 1, 2 and 3.

“This project shows how flexible the molding of Ductal®

can be and how easy it is to apply,” says Pierre Pallot,

R&D director with Bonna Sabla Group, which was

commissioned for this section of the contract by ADP’s

(Paris Airport Authorities) principal contractor, Brezillon.

“The challenge involved using light molded structural

panels that could be handled easily in confined spaces

and yet pleasing to the eye. This was important because

all of the airport access signs as well as advertising will be

on the panels.

Indeed, the combination of white Ductal® and stainless

steel baseboards, designed by architect Frédéric

Schlachet, is particularly attractive. This project is

exceptional not only for its size (600 panels measuring

3 x 1.2m meters; many of them curved concavely

or convexly to clad structural pillars), but also because,

with Ductal®, we can work like joiners. This new

concrete offers great flexibility of use in a wide

variety of shapes: cladding on handrail spandrels, special

rounded or corner pieces and even cupboards

with doors.“

solutionsEditorial

Lafarge Ductal® Newsletter - No. 2 - July 2005

DDuuccttaall®® :: aa wwoorrlldd ooff ccrreeaattiioonn Façade panels, double-skin cladding,mashrabiya, interior decoration,floor covering, urban furniture and design pieces - the Ductal®

applications developed by architects,builders, designers and decoratorsare inventive and varied, eye-catching and attractive, fun and yetpractical. We wanted to recognize

these achievements in a special“creativity” issue, to showcase theextraordinary creat ive energydeployed by designers who havesucceeded in exploring and integra-ting every advantage offered byDuctal®, to develop new architectu-ral and design solutions. Our hope is that this issue will encourage

them to pursue a partnership thatwe see as strongly designer-focused.We intend to accompany them in their endeavors, however daringand aesthetic or, on the contrary,sensible and functional.

Jean-François Batoz. Vice-President for Development

Project owner:

France’s first Ductal® bridge

As part of the project for abypass around the Saint-Pierre-la-Cour conurbation commissio-ned by the Mayenne GeneralCouncil,a 20-meter bridge wasbuilt over a railway line.The ten 20-meter prestressedgirders (without rebar) and the83 precast slabs they support areall made with Ductal®. Although only 25 mm thick, theprecast slabs support a conven-tional 20-cm concrete apron. All the girders and precast slabs were laid in just two days, thanks to the speed thistechnique affords.In addition, by using Ductal®, the volume of material used to build the bridge was reducedby half.Ductal® has a very low porosityand is particularly resistant to external stresses such as abrasion, pollution and harshweather. It also has a muchhigher resistance to ageing thanordinary concrete.

TechnologyOOrrllyy AAiirrppoorrtt PP00PPaarrkkiinngg LLoott::CCuussttoomm ddeessiiggnnOrly’s P0 parking lot, with its 600 panels in 50 different sizes, some of them curved, as well as 1137 m2 of concrete, showcases the vast wall covering possibilities offered by Ductal® concrete.

stop the pressstop the press

solutionsN° 2 - July 2005

Interview with architect Manuelle Gautrand

Special featurePress review

Solid decorationLightweight but extremely solid,

Ductal® is at the forefront of a

new generation of ultra-high

performance concretes that

designers are using to change

the face of interior decoration.

An alternative to steelDuctal® has been used in several

projects in Canada and is conside-

red a good solution by the U.S.

government for the potential

replacement of numerous bridges

that are showing structural

defects. The Massachusetts

Institute of Technology (MIT)

set up a research program to

develop a bridge profile best

suited for the Ductal® technology.

Figaro March 25, 2005

Techniques & ArchitectureFebruary/March 2005

Building bridges faster According to Benjamin Graybeal

of PSI Inc., before the develop-

ment of ultra-high-performance

concretes, the idea of building

a bridge that could last over a

century was unthinkable. In an

article in “Focus”, the Federal

Highway Administration’s official

publication, he suggests that

with UHPCs like Ductal®, today’s

bridges, in fact, last far longer

than the actual roads.

Concrete lacework to protect primitive art

The Metropolitan Lille Museum of Modern Art in Villeneuved’Ascq organized a design competition for the renovation andextension of the department housing its Outsider Art collections.The façade of the project presented by the winner, ManuelleGautrand, was a Ductal® mesh, inspired by the arts of intarsia and mashrabiya. In an interview, she gave us some insight intoher aesthetic and technical options

Manuelle Gautrand revisited the original function -seeing without being seen - of the Arabic-inspiredmashrabiya lattice. It serves a dual function here, opening onto views of the surrounding park while shielding works from direct sunlight.

FocusNovember 2004

Function and creativity

Does this concrete mesh really serve a purposeor is it just for looks?We had three objectives in mind. The entireMuseum, which was designed by Roland Simounet,has a strong mineral feel that we wanted to recap-ture by choosing materials as carefully as he didback then. Second, since outside art is often fragile,we needed to shield it while relying on natural lighting wherever possible. Our third goal was to integrate the plant world into the project, mirroring the very beautiful grounds surroundingthis section. The Ductal® lattice satisfied all three ofour objectives.

How did you actually use the concrete mesh?It will cover the main features of the project; all thepicture windows overlooking the park. It is madeof concrete-inlay panels through which light filters

to create a mashrabiya effect. The design, thoughfairly abstract, shows stylized plants climbing on arandom pattern. What we found most exciting was the possibility to create a lattice out of concrete and achieve asmooth, matte finish – light, very sober and refined. Technically, Ductal® was perfect for sculpting on extremely thin concrete plates (7-9 cmthick), almost three times thinner than conventio-nal concrete. Not only did this solve the weightproblem, but it makes hanging works easy andthey can be placed in front of picture windows.

Do you have other projects in which you’veapplied Ductal©?Here we capitalized on the material’s special properties to create a project in harmony with thearchitectural quality of the rest of the museum.Should the occasion arise, I’d also like to explorethe range of colors and textures that Ductal®

can offer.

Canadian Consulting EngineerJanuary/ February 2005

Structure and decorationIncreasing numbers of architects

are turning to Ductal®, which

works more like plastic than like

conventional concrete (injection

or extrusion). The architectural

firm, Mass, presented a mesh

application for urban furniture at

the latest Furniture Show in

Paris. The delicate lacework

made from Ductal® can serve

both structural and decorative

purposes.

Street furniture

Come wind or high tide

Fighting bombs with concrete? The search for new applicationsStudies (especially after the 9/11 terrorist

attacks in the United States and the Bali

bombing in 2002) have shown that buildings

in the immediate vicinity of an explosion can

be destroyed or severely damaged merely

from the impact of a shock wave or blast. In

Bali, some buildings within a 100-m radius of

the explosion did actually collapse.

That is why VSL Australia and the Advanced

Protective Technology for Engineering

Structures Research Group at Melbourne

University have attempted to assess the

strength of fiber-reinforced concretes like

Ductal®. They conducted full-scale trials in

Woomera, a region in southern Australia,

on 2.1-m panels ranging in thickness from

50 to 100 mm, which they subjected to

explosions equivalent to 6 tons of TNT, or a

2000-kPa pressure load exerted at 30 m.

According to VSL, Ductal® yielded results

which far exceeded even the most optimistic

forecasts.

Almost immediately afterwards, a first order

came in for Ductal® shielding to protect an

Australian embassy.

Further news to come soon!

SSaakkaattaa MMiirraaii ffoooottbbrriiddggee iinn JJaappaann The Sakata Mirai footbridge was built to

replace the old concrete bridge that had span-

ned the Niita River for 40 years. This was the

first structural application of Ductal® in Japan,

used for its mechanical properties and

strength to build a single span, 50 m long and

2.40 m wide. The deck consists of prefabrica-

ted, perforated components which make the

bridge more resistant to deformation and to

wind.

YYookkeemmuurrii ffoooottbbrriiddggeeThe Yokemuri footbridge is located in a

Japanese province known for its particularly

harsh weather.

It consists of a single 35.3-m span and a box-

girder cross section that has a constant height

of 0.95 m and a total width of 3.5 m. The

bridge was designed and built by Taisei using

Ductal® premix manufactured by Taiheiyo

Cement Corporation. Both companies have

Ductal® licenses. Because of Ductal®’s durability,

the bridge can withstand extreme temperature

variations, common to the region.

Materialstrength

Datasheet

What does the concrete lattice façade, desi-

gned by Rudy Ricciotti for the Museum of

Euro-Mediterranean Civilization (MUCEM), and

the new street furniture exhibited by the design

firm, Mass, at the Paris Furniture Show have in

common? They are both the products of ongoing

research into new transparent effects that, until

now, were beyond the reach of concrete. Ductal®

offers fluidity, resistance and ease-of-use more com-

monly found in cast or formed materials, which gave

Olivier Chabaud and Laurent Lévêque an opportu-

nity to stretch the limits of their creativity, invent a

new vocabulary for objects (benches, seats, parti-

tions, tree grates, etc.) and design a whole new

setting for outdoor urban spaces.

With Ductal®, each piece can take many different

shapes. The basic module is an open-work sheet,

almost like spatially deformable concrete lace. It

strikes a balance between void and solid space,

between fine and sturdy structure. Thanks to an

infinite variety of shapes, colors and motifs, the

modules make for individualized, yet swiftly

implemented design. For our two designers,

“Ductal® offers unique mechanical qualities and,

above all, unparalleled strength - even in thin

layers, as well as outstanding durability that can

be combined with anti-graffiti treatments.

Ductal® is well suited for public places, not only

because it is a tough material that can withstand

abuse and extreme climates; it is also particularly

conducive to creative applications. Due to its

exceptionally fine texture and a palette of custo-

mized colors (solution-dyed), Ductal® blends in

perfectly with the environment while conforming

to local architectural constraints.”

The secret to the lasting durability of Ductal® lies in its

controlled porosity and the fact that no networks of inter-

connected pores penetrate into the core of the material.

In ordinary concrete, in which porosity ranges between

10 and 15%, liquids and gases move through such

networks, even if the diameter of the pores is very small,

and end up penetrating into the core of the material.

Although slow, this process is inevitable.

In contrast, Ductal® does not form pore networks, due to

the materials chosen and the order in which they are

arranged. Only a few residual pores remain, scattered

throughout this very low-porosity material but they are

not interconnected. In addition, as shown in the two

photos, pore diameter is divided by a factor of between

10 and 50.

Architects, designers and decoratorsexplore every creative resource - texture, fineness, color, finishing and light – to develop a host of applications capitalizing on the vastrange of possibilities afforded byDuctal®. Olivier Chabaud and LaurentLévêque from Mass take us on a tour of the world of street furniture.

Durability: a guided tour of the microstructure

The word comes from porus in Latin and poros inGreek. The capacity of a material to contain spacesthat may or may not be interconnected, expressedas the ratio of the total volume of voids to thetotal volume of the medium (from FrenchHydrogeology Dictionary)

Porosity is a concept which considers, not poreshape and interconnections, but only pore volumes. However, like the concepts of pore, fromwhich it derives, and porous medium, which it characterizes, porosity refers to intersections ofsmall size.

“Porosity”, you said?

A facelift for the city

Photo : Christian Mc Manus

Ductal®Ordinary Concrete

Seated 22 meters above ground on the roof of the Laval

courthouse, the Campanile has symbolized the city since the

end of World War II. In the process of taking it down for

renovation, the tower was broken, so then challenge was

tobuild an exact replica. “We worked according to pictures

to prepare the mold drawings,” Gilles Deniau explained. He

is manager at Etablissements Deniau, the precaster commis-

sioned by Heulin to build this rather unusual project. “We

were expected not only to build an exact replica, but had to

solve two other problems. First, there was the weight of the

corbelled structure on an elevator shaft. Second, the cam-

panile had to be lowered into place from a street that was

too narrow for a large crane. Ductal® offered a

solution to all these problems. At equal resis-

tance, nothing can beat the lightness of the

material. We cast a 4-ton campanile in a special

formwork that would have weighed 22 tons

had conventional concrete been used. As a

result, a large crane could be installed on the

street to lift the three block components. The

entire block, 7 m in height and 2 m in diameter,

was put in place in only 48 hours, on May 10th

and 11th. The gray hue of the raw concrete gave

the new campanile just the aspect the architect

had been looking for, to recreate the bell tower

as people knew it.”

Credits No. 2 - July 2005

Editorial board - Jean-François Batoz - Mouloud Behloul Editor: Philippe Billon - Photo credits: Lafarge Photo libraryDesign/production: Agence All Write: +33 1 53 59 83 83 Printer: Imprimerie BM

News

For further informationIf you would like to receive news about Ductal®

solutions directly, just sign up on the www.ductal-lafarge.com website

Laval courthouse bell-tower

Reconstruction clocked at 48 hours

FRANCESCOPASSANITI: WHEN CONCRETEDRESSES AND DECKSOUT BATHROOMS

Due to Ductal®’s ultra-fine components,

the material is self-placing and can

faithfully reproduce textures from a

concrete stamping mold. Its structural

properties can also do away with the

constraints of passive reinforced concrete

frames, making very thin components

feasible.

Francesco Passaniti, who has been working

with concrete for eight years, guided by

his inspiration and imagination, used

Ductal®’s lightness and solidity to full

advantage to design a collection of

bathroom, indoor furniture and floor cove-

rings. These manifestations of his

creativity met with considerable success

at the most recent Maison & Objet Show.

The sculptor-interior architect presented

a range of interior design and decoration

products, including jewels such as his

rectangular bathtub, all in slender lines,

or a floor covering in 15 mm-thick, 1 x 1 m

slabs, copying the gray and white coat

of a Norman cow. The overall impression

is of a floor cast on the site.

wwwwww..ccoommppaaccttccoonnccrreettee..ccoomm

stop the pressstop the press

Formglas Inc., produces Ultra-thin Ductal® Chairs Formglas, considered the top North American manufacturer

of prestressed fiberglass and cement-based products for

architectural applications, recently shifted innovation into

high gear with a brand-new Ductal® license. With their

state-of-the-art pattern making capabilities, this collabora-

tion provides numerous opportunities for advanced product

innovation and customer-focused solutions that fully utilize

Ductal®’s combination of superior properties. The initiative

recently paid off when Vancouver architect, Omer Arbel

contracted Formglas to produce 4 unique, ultra-thin chairs

in Ductal® - for exhibition at the International Contemporary

Furniture Fair in New York and in the Lafarge booth at the

“ A I A ( A m e r i c a n

Institute of Architects)

National Convention

and Design Exposition”

in Las Vegas.

Concrete Workshop unleashes inspirationThe Concrete Workshop has moved off the beaten design

track with a collection of indoor furniture brimming with

inspiration. Its showroom demonstrates the degree to

which Ductal®’s molding properties foster creativity, beauty

and modernity. The planters, chairs, coffee tables and

benches shown in the photo below are all custom-made in

Ductal®. The Concrete Workshop directs its efforts at trans-

forming the outer structure of all types of concrete to pro-

duce decorative elements in a thousand potential combina-

tions. Ductal® multiplies the workshop’s inspirational sour-

ces, so that its artisans can create genuinely distinctive fur-

nishings, for and with you. Why not come for a visit at

wwwwww..aatteelliieerrbbeettoonn..ccoomm

Designer Woytek Sepiol wanted to imagine a sun shade

that would be capable of fitting most architectural

projects. Therefore, in collaboration with the precaster

Betsinor, he has designed a Ductal® sun shade that

is positioned away from the façade and secured using

stainless steel clips. This arrangement favours the entry

of natural light and its diffusion upwards, whilst limiting

the direct entry of sunlight. These sun shades are suited

to all types of façades (concrete, metal or curtain walls).

The mineral texture of the Ductal® sun shades helps

to reduce glare due to reflection and reduces noise

disturbances due to wind, rain, hail, etc. The narrow slats

also avoid the “caged” effect; and are available in

lengths ranging from 1.20 m to 3.00 m. Ultimately,

these sun shades can be arranged as needed, to limit

almost any visual discomfort while preserving sufficient

internal lighting and external visibility.

Contact: www.betsinor.com

solutionseditorialIn briefThe Lafarge Ductal® newsletter - no. 3 - March 2006

Footbridges:When engineering structures lose weightSeoul, London, Tokyo, Paris, Kyushu,Sherbrooke, … the list of cities withemblematic footbridges that enhan-ce their images of modernism andarchitectural creativity is rapidlyincreasing around the world.The rebirth of the footbridge inthese growing cities can be attributedto a common necessity to smoothlyand safely accommodate pedestriantraffic to the cities of tomorrow, aswell as plus architectural creativityand exceptional advancements innew material technologies.

The fact that an architect as creativeas Rudy Ricciotti considers “this fun-damental change in architecturecomparable to the invention of thejet engine for aviation”, is indicativeof the technological revolution thatconcrete has undergone in recentyears. Offering creativity and free-dom of design without compromi-sing strength, lightness and ease ofinstallation, Ductal® has opened theway to architects and contractorswith a passion for innovation and acommon desire for structural durabi-

lity and superior aesthetics. Thisissue describes details of these newfootbridges and enhances the deve-lopment of partnerships betweenLafarge and innovative designers.These partnerships involve impor-tant joint research and amazing newdesigns, which deserve to be called“Structural Art”!

Jean-François Batoz. Director of Development

Client:

Protection of swimming pools:Floreo® combines privacy and safety

Numerous owners of swimming

pools are currently seeking to

implement protective fences to

prevent from accident usually

affecting children, particularly in

France to comply with the norm

NFP 90-306 recently issued.

In Floreo®, designer Gérard

Tuduri has created an original,

innovative solution.

The combination of minerals and

vegetables makes efficient

barrier but one forget that the

fence exists. The container,

made of Ductal®, combines fines

lines, lightness and great

strength.

The fencing slides into the posts

and requires no hardware. The

gate is then fitted with a double

lock.

This new product is distributed by

the precaster Bonna Sabla to pro-

fessionals serving the swimming

pool and landscaping markets.

Contact:

[email protected]

techno

In brief

Sun shade:a design for all façades

solutionsN° 3 - mars 2006

reportagePress review

An ecological high risebuilding for the ChineseArchitect Jacques Ferrier, in part-nership with Lafarge, has develo-ped a concept for an ecologicaltower intended for China. Thisconcept, which could be as muchas 250 m high, is based on a self-supporting facade made of aDuctal® web, to ensure stability.

Very well reinforcedconcreteWith an arch spanning 120 m, adeck less than 3 cm thick and nomiddle supports, the Footbridgeof Peace in Seoul, Korea (desi-gned by Rudy Ricciotti), symboli-zes gracefulness… Constructedentirely in Ductal® includingmetallic fibres reinforcement,this innovative concrete foot-bridge is lighter, stronger andmore flexible; capable of suppor-ting loads up to 10 times morethan bridges made with conven-tional concrete.

Le Moniteur - Dec. 2005

d’Architecture - Dec. 2005

Ultra-thin Ductal ®

Canopies: a world firstThe Shawnessy LRT Station inCalgary has the world’s first thin-shelled precast Ductal® canopyroof system (see p. 4). As a “worldfirst”, the City of Calgary requiredthat a full-scale prototype be sentto the University of Calgary’sCentre for Innovative Technology,for a series of extensive load tests.The tests concluded that the cano-py carried full-factored live anddead loads without cracking andeasily surpassed the test criteria.

“Today, it is almost impossible tobuild a bridge that will last formore than a century or even 75 years, using conventional techniques”, explains BenjaminGraybeal of PSI, a constructioncompany working for the FHWA.The scene is set: the replacementof aging bridges and the necessaryconstruction of new bridgesdemanded a solution which wouldboth increase the life of bridgesand reduce maintenance costs.In order to subject this new material to a series of tests (to confirm the durability and economics that Ductal® bridges or footbridges in France, SouthKorea, Japan and Canada havedemonstrated), the FHWA approved two pilot bridges; one in Iowa and the other in Virginia.

In the first place, the compositionof Ductal® alters the perspective of its performances in relation toconventional concretes and even

metal structures. “Ductal® contains2 % of metal fibres”; noted DeanBierwagen of the Iowa TransportDepartment. “These fibres, 0.2 mm in diameterand 12.7 mm long, are the secretto the strength of this concrete. In addition, the density of thematerial ensures a level of imperviousness which considerablyreduces the risk of corrosion intime.” In building the first bridge in Ductal® in the United States, in Wapello County in Iowa, theFHWA's intention was to test the material’s performancesone–by- one, starting withstrength, permeability and the cost of maintenance.

“One of the series of tests enabledus, for example, to show thatDuctal® involves the use of farfewer materials, thereby enablingus to build sleeker bridges, comparable to steel bridges: whichare lighter and stronger at the

same time” confirms BenjaminGraybeal. “Furthermore, the girdersare much easier to transport andinstall, which means saving timeand money.”

The FHWA subjected Ductal®

to compression tests at 196 mega-pascals, a long way from the usual28 megapascals for conventionalconcrete. Similarly, the salt andchloride resistance tests for roads,revealed performances 100 times better than those of conventionalconcretes.

“Lastly”, concludes BenjaminGraybeal, “in terms of cost, ifDuctal® at first appears to be moreexpensive, it is essential to considereach project on its benefits. Thelower cost of construction andextended life of the structure oftenmake it very attractive in economicterms.”

The test bridge in Wapello County Iowa: 3 girders with a span of 33 m:The simplicity of installation considerably reduces costs.

Canadian Journal for Civil Engineering

Dec. 2005

The world’s first Ductal®, roadbridge, the Shepherds Bridge,was built 150 km north ofSydney (Australia), to replace anold wooden bridge. With a spanof 15 metres and a width of 21 metres, the bridge is made upof 16 Ductal® girders, 1.3 mapart, which support a reinforcedconcrete slab cast directly on a

stay-in-place form, also made of Ductal®.

The originality of this structure,which was designed and valida-ted by tests carried out by theUniversity of New South Wales,combines exceptional resistanceto bad weather and traffic with aparticularly low weight: 280 kg/m

for the girders and a thickness of only 25 mm for the Ductal®

left in place formwork. Designedand built by VSL-Australia, onbehalf of the Australian (RTA)Roads and Traffic Authority, the Shepherds bridge providesdurability, strength and low maintenance costs.

Durability/strength/cost of maintenance

The Shepherds Bridge in Australia opens the way

Enjeux Les Echos - Nov. 2005

Lafarge “YoungArchitects” Prize: won by the H20 team Intended to promote the mostoriginal and contemporarydesigns, this competition, orga-nized by Lafarge, awarded theprize to Charlotte and Jean-Jacques Hubert of the H20 team,for their urban furniture andequipment made of Ductal®.

Bridges in Ductal®:Tested and approved by the American Federal Highway Administration

Faced with the need to replace a large

number of deteriorating road bridges

in the USA, the Federal Highway

Administration (FHWA)

decided to test the

performances of Ductal®

with a full scale

demonstration!

More than any other engineering structure,

a footbridge can give a city an identity

and is, therefore, one of the most sensi-

tive infrastructures. For instance, the Millennium

footbridge in London, the Solférino footbridge in

Paris or the Ductal® footbridge in Seoul. The archi-

tectural aspect takes pride of place and the rules of

aesthetics associated with slenderness ratio, colour

or texture take priority in the choice of materials.

And, whilst steel structures meet many of these

requirements, it is often to the detriment of

maintenance costs. Laminated wood, which is

sometimes an alternative, is far less durable than

concrete structures. In its conventional composi-

tion, concrete does not allow for the thin, elegant

lines the imagination of architects demand. By

combining strength, lightness and ductility, ultra-

high performance Ductal® has opened the door to

new possibilities, with footbridges of innovative

design and creativity.

Slenderness, fineness and colour

Civil engineering structures are generally designed

to support their own weight at 65 % of the bea-

ring capacity. The reduction of dead load of struc-

tures made with Ductal®, by an average of 3,

increases the usual slenderness of footbridges. The

primary condition for designing the structure had

become the deformation of materials and not their

strength. Ductal® now offers a significant advan-

tage, since all geometrical shapes are possible,

arches, rigging structures, isostatic bays, mesh

structures, etc. Furthermore, the bending strength

of this material allows for the design of structural

elements without passive reinforcements, allowing

for very thin decks of approximately 3 cm instead

of the usual 12 cm with other concretes.

Ductal® may be coloured, leaving designers to use

their imagination.

Durability and little maintenance

Ductal® consists of a very dense, closed matrix

which prevents the ingress of aggressive elements.

With its exceptional durability, Ductal® applications

typically require little or no maintenance; another

argument for local authorities seeking structures

that reflect a modern image, without committing

themselves to maintenance budgets in the long

term.

Bridges and footbridges zoom

Technical data sheet

The characteristics of Ductal®-FO certified by the CSTB

The footbridge at Yokemuri consists of a singlespan, 35.30 m long. The box cross-section has a constant height of 0.95 m and a total width of 3.50. The durability of Ductal® enables it towithstand the region’s extreme climates.

The Sakata Mirai footbridge in Japan: no passivereinforcement for this footbridge with a span of50 m, a width of 2.4 m and a deck 50 mm thick.

The “Conseil Général” of the Mayenneordered a bypass from the town ofSaint-Pierre-la-Cour.It was in this context that the first bridge in France made of Ductal®

was built to cross a railway line. Thisbridge, with a span of 19 m and 12.6 m wide, supports a continuousreinforced concrete road of 7.6 m, apavement and a cycle track.

The advantage of its design is that ituses all the properties of Ductal® to a maximum.gain in materials, thanks to a lighterstructure and an increase in the slenderness ratio of girders. The 10 girders are pre-stressed by pre-tensio-ned strands. With the exception of the linking steel with the slab cast onsite, the girders contain no secondaryreinforcement or shear reinforcement.

A technique which results in a bridgetwice as light as a conventional concrete solution. The weight of eachgirder is 9 tonnes, making handling onsite easier. The Saint-Pierre La Courproject required only one day for casting and one day for the bonding of the concrete slab.Durability: the characteristics of thestructure are enhanced by the fact thatthe underside of the concrete deckand its reinforcements are protectedagainst any damage.Durability that limits maintenance budgets and provides a more globallyeconomic solution.

Saint-Pierre-la-Cour:A railway bridge that is twice as light

Footbridges built with Ductal®:No limit to creativity

To make Ductal® easier to use with organic fibres for architectural applica-

tions, Lafarge has had a complete technical evaluation of the material car-

ried out a French certification body, the CSTB. This evaluation, which has

been in place since November 2005, sets out all the characteristics of

Ductal®-FO, both in terms of mechanical strength and durability.

The properties certified by the CSTB prove the advantage of Ductal®-FO for the

manufacture of non-structural elements, such as:

- thin architectural panels and shells

- cornice outlines

- urban furniture, etc.

This technical evaluation of the material will greatly facilitate obtaining

Technical Opinions, Atex or other certification for products or structures

made of Ductal®-FO.

This CSTB certification is available on our internet site:

www.ductal-lafarge.com

solutions No. 3 - March 2006

Editorial Committee -Jean-François Batoz - Mouloud Behloul -Editor: Philippe Billon - Credits: Photothèque Lafarge - Design/pro-duction: Agence All Write: 01 53 59 83 83 - Printer: Imprimerie BM

news

In brief

For more information

Idéo Bain: The rough cast bathroom Composites pour le Sanitaire et Industrie (CSI) presented anew range of wall cladding and floor panels made of Ductal®

at the Idéo Bain shows, which was held at Porte de Versailles,January 17t - 22. This wall cladding demonstrates an incredible range of textures and colours, allowing for thedesign of truly new bathrooms. Contact : www.csi-sas.com

Greenbuild 2005 Atlanta: Lafarge platinumsponsor of EcoSmart Condo Ductal® ramps were displayed Nov. 8-10 at the EcoSmart

Sustainable Condo, during the “Greenbuild International

Conference & Expo” (annual conference of the U.S. Green

Building Council). The Expo, with 600 exhibitors, attracted

nearly 10,000 participants (specifiers, architects and engi-

neers) seeking the latest

technologies for LEED-cer-

tified buildings. Lafarge is

Platinum sponsor of the

EcoSmart Condo: designed

by *Busby & Associates, to

address the challenges of

urban sustainability.

Pour en savoir plus : www.greenbuildexpo.orgwww.substainablecondo.com

If you would like to receive news of Ductal® solutions directly, register on our web site:

www.ductal-lafarge.com.

Prizes and distinctions

Ingenuity, creativity, innovations, The United States do honour to Ductal®

The 24 off-white Ductal® canopies at the Shawnessy LRT Station in Calgary, Canada

(designed by Enzo Vicenzino), demonstrate a technological revolution and continues

to win awards on the other side of the Atlantic; and, recently, was named one of two

“Finalists”, competing for the prestigious 2006 CERF/Charles Pankow Prize for

Innovation This award acknowledges tech-

nological innovation and design with cons-

truction materials that increase productivity

and performance in industry.

To date, the project has received awards

from: APEGGA (Association of Professional

Engineers, Geologists and Geophysicists of

Alberta), ACI (American Concrete Institute)

2 from PCI (Precast/Prestressed Concrete

Institute) and was also a 2005 ASTech

(Alberta Science & Technology Foundation)

Finalist.

In brief

“Mad” furniture from the “Atelier du Béton”

“Arlequin” Table from Béton Concept

Concrete is the guest ofhonour at the furniture show

Ductal® was used for many of the

creations exhibited, January 6th to 9th

in the brand new “concrete home” area

of the Salon du Meuble (furniture trade

fair). Entirely given over to concrete furni-

ture and objects, it brought together (in

a space of 300 m2 devoted to furniture

designed from Ductal®), ten designers,

architects and decorators, who exhibited

their prototypes of indoor or outdoor

furniture, baths, sinks, floor tiles, light

fittings, etc.

By exhibiting their latest creations: tables,

chairs, vases, planters, etc., they proved

that this enthusiasm is now shared by

the general public, which are increasingly

bringing concrete into their homes, with

solid and unique creations.

Contacts :

www.atelierbeton.com,

www.beton-concept.com

dabadabada, the star of the Idéo Bain ShowArchitects & Designers AnneDurand and Patrick Millet exhibi-ted their first collection ofbathroom furniture at the IdéoBain Show, under their trade-mark, “dabadabada®”. “Awareof the fact that the new concretescould be used for things otherthan sinks and square showertrays, we have imagined and desi-gned a bathroom collection, thedesign of which should be strong enough to express thepotential of this new material Ductal®“, they explained. Eachsink, may be made from a colour palette that is renewedevery year. Their work was awarded the Idéo Bain Show special prize by a jury of professionals. Contact : www.dabadabada.fr

solutionseditorialin brief

The Lafarge- Ductal® newsletter - No. 4 - October 2006

Street furniture: the new art of city living?

techno

solutions N0 4 - October 2006

Editorial committee: Jean-François Batoz - Mouloud Behloul -Lisa Birnie - Philippe Billon - Photo credits: PhotothèqueLafarge - Design/production: Agence All Write : +33 (0)1 53 59 83 83 - Printed by: Imprimerie BM

Special report

If you would like to receive news about Ductal® solutions directly,

simply sign up on the

www.ductal-lafarge.com website

Decorative Roadways

Inauguration of the first Ductal®

highway bridge in North America

The Bordeaux tram system:anti-slip and safety issues

Lafarge Young Architects Competition :

and the winner is… the H20 agency

Tramway safety is primarily a matter of

ensuring clear marking and signage to

designate the areas of public roadway this

form of public transport will occupy as

opposed to vehicles and pedestrians. The

designers entrusted with this task, the

BLP/Signes/EDP consortium, came up with

a fish scale-shaped aluminium track alter-

nating every 10m -- with an insulating

track made from Ductal® to prevent stray

current propagation.

"In practice," explains Pascal Monteil of

Bonna Sabla, which was responsible for

the project, "the surface wear caused by

vehicle traffic at junctions made the alu-

minium very slippery. The Ductal® track,

produced with an orange-peel and rice-

grain finish, offers a particle distribution

highly conducive to anti-slip properties. Its

slip coefficient was unaffected by wear

and the anti-slip effect was longer las-

ting."

A total length of 2,000 metres is to be laid

by the end of the first half of the year.

"One important aspect of the project is

the elegance achieved by using different

shades of grey in the materials," adds Mr.

Monteil, "so the added advantage of

Ductal® is that it blends in perfectly with

the colour harmonies devised by the archi-

tects and landscape designers."

As part of its policy of supporting young

talent, Lafarge has instituted a competi-

tion for architects under the age of 40,

with a goal to create

innovative street

furniture. The

jury prize was

awarded to

the H20

agency

which

entered a

comprehensive

range of benches and chairs making the

most of all Ductal®'s superior properties

including strength, ductility and colour

options. Fun and appealing, with roun-

ded lines

and a

medley

of

colours,

the range

designed

by Charlotte and

Jean-Jacques Hubert gives a

new slant to the shapes and forms that

city authorities traditionally provide for

their residents.

in briefSwinging cities

“Azuly®”, a registered trade-

mark of BMI, a company specia-

lising in the manufacture of

mineral lamp-posts for upmar-

ket street-lighting, has launched

“Swing”, a collection of street

furniture designed by Studio

Design Francesco Passaniti. The

range of products are made

from Ductal® ultra-high-perfor-

mance concrete and consists of

a bollard, wheel deflector,

bench, planter and a litter bin --

available in 10 different colours

to blend harmoniously into any

urban environment. With its

reassuring rounded forms and

hollow designs for astonishing

transparency and lightness, the

entire range is inspired by

movement and echoes the

rhythm of the city and its resi-

dents.

Elegance aside however, the

great advantages of this street

furniture are its durability and

ease of maintenance. Ductal®

does away with the need for

passive reinforcement and

opens the door to a design of

extraordinary purity, yet with

almost the abrasion resistance

of granite.

Simplicity and ease of maintenance for water treatment plantsThe Gold Bar wastewater treatment

plant in Edmonton, AB, Canada, is the

sole facility serving the city of

Edmonton and its surrounding sub-

urbs. The plant's collection tanks are

located directly over the sheet-steel

plate-settlers , so structural strength,

durability and lightness were key

requirements.

Traditional cement would have called

for extra support and stainless steel

might have seemed the logical choice

for this project, but the cost was pro-

hibitive. Design consultants, Stantec,

was familiar with Ductal®'s unique

properties and determined that

Ductal® troughs offered a viable, new

solution. As a result, the physical pro-

perty requirements were met and the

solution generated the following

advantages:

• greater structural strength, to sim-

plify design and reduce weight,

• high resistance to the corrosive was-

tewater environment,

• a lighter structure, making installa-

tion easier,

• a dense, smooth surface finish to

prevent water infiltration and conta-

mination,

• easy to clean.

A final and undeniable advantage for

a structure of this kind, and an argu-

ment that won the

day!

Cities are paying more attention than ever totheir image. The quality of the setting theyprovide for their citizens increasingly reflectsan art of city living that is elegant, comforta-ble and multi-purpose.A number of artists and designers have beeninspired to create lines of street furniture sodistinctive as to be a matter of civic pride,carrying an instantly perceptible mark ofmodernity. Lines that combine safety, elegan-ce and utility, taking advantage of all thesuperior qualities of ultra-high-performanceconcrete: strength, durability, ductility, quali-

ty of finishing and range of colours.Reinvented by active partnership betweenLafarge and architect designers, this newstreet furniture offers local authorities whattheir residents want in terms of convenienceand cleanliness, but also in terms of parkingcontrol or cycle-stands on cycling lanes, for awhole new approach to the art of city livingin a mineral environment.

Jean-François BatozVice-President, Ductal® Development

A single span, 55-metre, pedestrian bridge will soon

stretch across 8 busy lanes of traffic, in Calgary, Alberta,

Canada. This prototype bridge, called the “GE5” repre-

sents a "first" to utilize its innovative design as part of an

ongoing program for the City of Calgary. Approaching

motorists will be treated to the amazing sight of 144

unique Ductal® fish, installed along an attractive precast

retaining wall - also built by Lafarge. Artists Violet Costello

and Bob Thomasson created a concept including precast

concrete walls with waves, in two different colors to simu-

late the sky and water -- populated with colored trout jum-

ping above the water and non-colored trout swimming in

the water. Each fish is approximately 4.5 m x 1.2 m, 25mm

to 65 mm thick and weighs less than 400 kilograms.

The unique 24 ultra-thin, off-white Ductal® canopies, that

form the station's eye-catching, shelters was recently

selected to receive a prestigious “fib Award (fédération

internationale du béton/International Federation for

Structural Concrete) for Outstanding Concrete Structures.

A variety of projects were submitted from 14 different

countries. To date, the project has also received:

• the CERF 2006 Award for Innovation (Civil Engineering

Research Foundation)

• two 2005 PCI Design Awards (Precast/Prestressed

Concrete Institute)

• the 2005 ACI Award of Excellence for design and cons-

truction in concrete (American Concrete Institute)

• The 2005 APEGGA (Association of Professional

Engineers, Geologists and Geophysicists of Alberta) Project

Achievement Award.

Shawnessy Station in Calgary winsinternational awards

America's first Ductal® highway bridge, in Iowa's Wapello

Country, is the result of five years of collaborative research

and development between the Federal Highway

Administration (FHWA), the Iowa Department of

Transportation, Iowa State University and Lafarge North

America. The bridge was officially opened (May 5/06) by Vic

Perry, Vice President and General Manager, Ductal®, Lafarge

North America, and Brian Moore, Wapello County Engineer

and Zoning Administrator. With a single-span, three-beam

cross section, the bridge has three 33m Ductal® girders with

no rebar for shear stirrups - a significant step towards “The

Bridge of the Future”. The girders were produced by

Lafarge's precast operations in Winnipeg, Manitoba and

delivered to the site in Iowa for installation by local contrac-

tor, Bloomfield Bridge and Culvert. Ductal® achieved a com-

pressive strength for this application of 2,100kg/cm2 and a

flexural strength of 421kg/cm2.

DUCTAL_4_GB_AF 18/10/06 16:03 Page 1

What is the thinking behind this highly "graphic"

building?

Dominique Marrec : We wanted to focus on the mine-

ral nature of the site and propose a building that acts as

a continuation of the ground surface and emerges like a

deformation of that surface.

It was this approach that gave us the idea of a skin that

would blur distinctions between traffic flows and building

while giving the site a strong visual identity. Two imple-

mentation techniques come together here: heavy prefa-

brication and siding, as the 3cm thick skin provides a

pavement that is partly open to traffic and rises up, swee-

ping away any thickness, to lose itself in the sky.

The Lego-like framework we devised, as well as offering

anti-slip properties, gives colour-stippling effects that

break up the play of lights and mirrors from the tinted

external exterior bonded glass bays. This skin uses Ductal®

not only for its structural properties but also for its visual

aspect, its depth of colour and quality of finish. The mar-

riage of this project concept with the performances of

the chosen material enabled us to offer users maximum

freedom of choice in their use of the space available.

There was no predetermined plan for the interior layout.

Instead, it was tailored to their aspirations and subse-

quently we came along to cut out the skin, virtually with

a box-knife, to create the openings, patio and access

points.

Just like the Ductal®/bonded glass facades, this pro-

ject is made up of a multitude of technical details

that create its overall purity of line. What were the

keys to this success?

solutionsN0 4 - October 2006

special report architecturepress review

realisation

The long life of aqueductsThe Shin-yahagigawa canal, built in the

1960’s in Japan's Hosokawa province, was in

need of complete restoration. The Regional

Department of Japan's Ministry of

Agriculture, Forests and Fisheries opted for a

solution in 3cm thick ultra-high-performance

concrete to ensure an extended lifetime for

this 440m aqueduct of vital importance to the

province's irrigation system.

The use of Ductal® greatly simplified the repair

work since it was possible to lay a new

conduit directly over the old without restric-

ting the flow of water through the aqueduct.

This repair work was orchestrated by the

japanese Ductal® license TCC.

Street lightingMake way for mineralAt the Lumiville trade show, BMI

Azuly unveiled a new range of

street equipment, relying heavily

on mineral solutions for design

and decoration. One example

was its furniture made from

Ductal® concrete, which allows

for much slimmer structures,

and opens the door to new pos-

sibilities for elegant designs in a

wide variety of colours.

Astonishing concrete!A fascinating "Concrete Home

Space" display at the Paris

Furniture Show featured a num-

ber of prototypes illustrating new

applications for concrete, and

particularly for the ultra-high-per-

formance concretes such as

Ductal®, in the world of furnis-

hings and interiors. Concrete tur-

ned chameleon, and led the way

to innovative creativity!

UHPFRC increasingly usedin building and construc-tion?The now widely recognized qua-

lities of ultra-high-performance

fibre reinforced concretes are

attracting growing interest from

designers because they offer

architectural opportunities that

were previously difficult to achie-

ve or better suited to materials

other than concrete.

Roadways NetworkJune 2006

Artravel - April/May 2006

BTP Magazine - March 2006

The return of the skyscraperFor Jacques Ferrier, designer of

the Hypergreen tower, "there is

a sort of natural contact bet-

ween the idea of developing an

environment-friendly tower and

using the advantages offered by

ultra-high-performance concre-

tes such as Ductal®".

La Tribune - September 2006

The dramatic events of recent years, whether due

to terrorist threat or the erratic forces of nature,

have demanded that we need to rethink the fun-

damental design of buildings if they are to fulfil

their primary task of protecting the people who

use them. What makes this need all the more

pressing is that advances in technology have

affected many segments of society, but building

construction has remained largely on the sidelines

of this move towards scaled-up protection

against threats of a new order.

Protecting the inhabitants

of high-risk buildings

Recent events have highlighted the vulnerability

of building exterior claddings. Ductal®

Blastwalls™ offers a new and highly effective

solution for resistance to powerful explosions and

high winds. Blastwalls™ made from Ductal®,

jointly developed by Lafarge and Composite

Technologies of Calverton, New York, have been

designed, tested and manufactured to resist ext-

reme blast forces.

In practice, Ductal® is used either as a substrate

or a finished surface to provide facades that are

more resistant and/or lighter. The innovation lies

in producing a façade that absorbs the force of a

blast by curving or bending, and, most impor-

tantly, that does not transfer the full force of the

blast to the building superstructure. Even better,

the facade has the ability to absorb the impact of

shells, debris and projectiles. This new application

for Ductal® offers a radically innovative solution

for all new or existing buildings exposed to the

risk of explosion, including all buildings previous-

ly deemed to require anti-blast walls with high

wind resistance, such as universities, embassies,

government buildings, military installations, port

facilities and, of course, chemical and petroleum

plants.

A double mineral skinInterview with architect Dominique Marrec

The RATP administrative centre in Thiais is responsible for the traffic management of 300 buses and provision of 24-hour facilities for 800 drivers. Located in an industrial zone on the outskirts of Paris, this award-winning project,designed by agency ECDM, is an ode to the qualities of minerals. Mirroring the variety of coatings within the busdepot, a double skin first follows and then lifts the pavement. The result is a non-directive setting in which users are free to determine what they want to conceal and what they want to leave open to view.

Technical fact sheet

Ductal®

Blastwalls™ forindestructiblebuildings

Dominique Marrec : The project is really founded

on the commitment of all concerned: Philippe

Isembeck of RATP, Vincent Souyri of SEDP,

Dominique Stoeux of Betsinor and Léopold

Lombard and Mouloud Behloul at Lafarge. As a

result of all their work, we were able to come up

with the unusual and innovative implementations,

throughout the process of researching the project.

While the Ductal® skin provided a certain number

of solutions to the problems raised by our choices,

it was really because all concerned put their ener-

gies into the studies, constructing prototypes, car-

rying out tests, creating the moulds that would

respond as fully as possible to the imperatives

imposed on us by our own demanding standards

of rigour and efficient use of resources.

DUCTAL_4_GB_AF 18/10/06 16:03 Page 3

solutionseditorialin brief

The Lafarge- Ductal® newsletter - No. 4 - October 2006

Street furniture: the new art of city living?

techno

solutions N0 4 - October 2006


Special report




Decorative Roadways

Inauguration of the first Ductal®

highway bridge in North America

The Bordeaux tram system:anti-slip and safety issues

Lafarge Young Architects Competition :

and the winner is… the H20 agency

Tramway safety is primarily a matter of

ensuring clear marking and signage to

designate the areas of public roadway this

form of public transport will occupy as

opposed to vehicles and pedestrians. The

designers entrusted with this task, the

BLP/Signes/EDP consortium, came up with

a fish scale-shaped aluminium track alter-

nating every 10m -- with an insulating

track made from Ductal® to prevent stray

current propagation.

"In practice," explains Pascal Monteil of

Bonna Sabla, which was responsible for

the project, "the surface wear caused by

vehicle traffic at junctions made the alu-

minium very slippery. The Ductal® track,

produced with an orange-peel and rice-

grain finish, offers a particle distribution

highly conducive to anti-slip properties. Its

slip coefficient was unaffected by wear

and the anti-slip effect was longer las-

ting."

A total length of 2,000 metres is to be laid

by the end of the first half of the year.

"One important aspect of the project is

the elegance achieved by using different

shades of grey in the materials," adds Mr.

Monteil, "so the added advantage of

Ductal® is that it blends in perfectly with

the colour harmonies devised by the archi-

tects and landscape designers."

As part of its policy of supporting young

talent, Lafarge has instituted a competi-

tion for architects under the age of 40,

with a goal to create

innovative street

furniture. The

jury prize was

awarded to

the H20

agency

which

entered a

comprehensive

range of benches and chairs making the

most of all Ductal®'s superior properties

including strength, ductility and colour

options. Fun and appealing, with roun-

ded lines

and a

medley

of

colours,

the range

designed

by Charlotte and

Jean-Jacques Hubert gives a

new slant to the shapes and forms that

city authorities traditionally provide for

their residents.

in briefSwinging cities

“Azuly®”, a registered trade-

mark of BMI, a company specia-

lising in the manufacture of

mineral lamp-posts for upmar-

ket street-lighting, has launched

“Swing”, a collection of street

furniture designed by Studio

Design Francesco Passaniti. The

range of products are made

from Ductal® ultra-high-perfor-

mance concrete and consists of

a bollard, wheel deflector,

bench, planter and a litter bin --

available in 10 different colours

to blend harmoniously into any

urban environment. With its

reassuring rounded forms and

hollow designs for astonishing

transparency and lightness, the

entire range is inspired by

movement and echoes the

rhythm of the city and its resi-

dents.

Elegance aside however, the

great advantages of this street

furniture are its durability and

ease of maintenance. Ductal®

does away with the need for

passive reinforcement and

opens the door to a design of

extraordinary purity, yet with

almost the abrasion resistance

of granite.

Simplicity and ease of maintenance for water treatment plantsThe Gold Bar wastewater treatment

plant in Edmonton, AB, Canada, is the

sole facility serving the city of

Edmonton and its surrounding sub-

urbs. The plant's collection tanks are

located directly over the sheet-steel

plate-settlers , so structural strength,

durability and lightness were key

requirements.

Traditional cement would have called

for extra support and stainless steel

might have seemed the logical choice

for this project, but the cost was pro-

hibitive. Design consultants, Stantec,

was familiar with Ductal®'s unique

properties and determined that

Ductal® troughs offered a viable, new

solution. As a result, the physical pro-

perty requirements were met and the

solution generated the following

advantages:

• greater structural strength, to sim-

plify design and reduce weight,

• high resistance to the corrosive was-

tewater environment,

• a lighter structure, making installa-

tion easier,

• a dense, smooth surface finish to

prevent water infiltration and conta-

mination,

• easy to clean.

A final and undeniable advantage for

a structure of this kind, and an argu-

ment that won the

day!

Cities are paying more attention than ever totheir image. The quality of the setting theyprovide for their citizens increasingly reflectsan art of city living that is elegant, comforta-ble and multi-purpose.A number of artists and designers have beeninspired to create lines of street furniture sodistinctive as to be a matter of civic pride,carrying an instantly perceptible mark ofmodernity. Lines that combine safety, elegan-ce and utility, taking advantage of all thesuperior qualities of ultra-high-performanceconcrete: strength, durability, ductility, quali-

ty of finishing and range of colours.Reinvented by active partnership betweenLafarge and architect designers, this newstreet furniture offers local authorities whattheir residents want in terms of convenienceand cleanliness, but also in terms of parkingcontrol or cycle-stands on cycling lanes, for awhole new approach to the art of city livingin a mineral environment.

Jean-François BatozVice-President, Ductal® Development

A single span, 55-metre, pedestrian bridge will soon

stretch across 8 busy lanes of traffic, in Calgary, Alberta,

Canada. This prototype bridge, called the “GE5” repre-

sents a "first" to utilize its innovative design as part of an

ongoing program for the City of Calgary. Approaching

motorists will be treated to the amazing sight of 144

unique Ductal® fish, installed along an attractive precast

retaining wall - also built by Lafarge. Artists Violet Costello

and Bob Thomasson created a concept including precast

concrete walls with waves, in two different colors to simu-

late the sky and water -- populated with colored trout jum-

ping above the water and non-colored trout swimming in

the water. Each fish is approximately 4.5 m x 1.2 m, 25mm

to 65 mm thick and weighs less than 400 kilograms.

The unique 24 ultra-thin, off-white Ductal® canopies, that

form the station's eye-catching, shelters was recently

selected to receive a prestigious “fib Award (fédération

internationale du béton/International Federation for

Structural Concrete) for Outstanding Concrete Structures.

A variety of projects were submitted from 14 different

countries. To date, the project has also received:

• the CERF 2006 Award for Innovation (Civil Engineering

Research Foundation)

• two 2005 PCI Design Awards (Precast/Prestressed

Concrete Institute)

• the 2005 ACI Award of Excellence for design and cons-

truction in concrete (American Concrete Institute)

• The 2005 APEGGA (Association of Professional

Engineers, Geologists and Geophysicists of Alberta) Project

Achievement Award.

Shawnessy Station in Calgary winsinternational awards

America's first Ductal® highway bridge, in Iowa's Wapello

Country, is the result of five years of collaborative research

and development between the Federal Highway

Administration (FHWA), the Iowa Department of

Transportation, Iowa State University and Lafarge North

America. The bridge was officially opened (May 5/06) by Vic

Perry, Vice President and General Manager, Ductal®, Lafarge

North America, and Brian Moore, Wapello County Engineer

and Zoning Administrator. With a single-span, three-beam

cross section, the bridge has three 33m Ductal® girders with

no rebar for shear stirrups - a significant step towards “The

Bridge of the Future”. The girders were produced by

Lafarge's precast operations in Winnipeg, Manitoba and

delivered to the site in Iowa for installation by local contrac-

tor, Bloomfield Bridge and Culvert. Ductal® achieved a com-

pressive strength for this application of 2,100kg/cm2 and a

flexural strength of 421kg/cm2.

DUCTAL_4_GB_AF 18/10/06 16:03 Page 1

solutionsin brief

The Lafarge- Ductal® newsletter - October 2006

250 years of innovation on displayLongevity or creativity? Symbol of an era,or product of an imagination that knowsno limits? What is the connection bet-ween the Pantheon in Rome, the CNITbuilding in Paris La Défense or theMUCEM building in Marseilles, if not thesame passion for a material capable ofendlessly reinventing itself: concrete? Butthe extraordinary ascension of this "kindof powder which, by nature, produceswonderful results" (Vitruvius, 1st centu-ry) is closely associated with the industrial era. For the past 250 years, thehistory of innovations achieved by architects and engineers working together has been closely associatedwith the history of Lafarge. A partnershipthat, over the past century and a half,has made possible the construction ofbuildings symbolising, each more strongly than the last, progress, urban

development and the towns and cities inwhich we live today. From ferro-cementships to translucent concrete, the exhibition organizers have lined up aseries of surprises and innovations forthe public and industry professionals, toadmire. The exhibit demonstrates justhow much concrete shapes our lives andsurroundings, whether in the form of astructure, façade, jewellery, furniture, oran endless range of other products.A diversity of often little-known applica-tions which, with the arrival of Ductal®, isexpanding at a rate limited only by thecreativity of architects and designers. Inother words, an unlimited one!

Prepare to be astonished!

Jean-François Batoz, Vice-President,Ductal® Development

solutions Special Edition - October 2006





When concrete spells design

"Béton: étonnez-

vous" has more

than one surprise in

store. Incredibly slim

benches stand side

by side with poufs

(ottomans) and an

"Ellen" bookshelf

made from solution-dyed caissons - all creations in Ductal®

by Francesco Passaniti. Concrete also shows its versatility in

the form of street furniture, a bath, a desk, a chair and

even jewellery - in the hands of Patrice Fabre - or a perfu-

me bottle designed by Thierry Bogaert.

Elsewhere, concrete meets transparency with the Ductal®

formwork bench designed by Olivier Chabaud and Laurent

Levêque and made from a slim, flat sheet of open-work

mesh, like the lace-work of a mashrabiya (Arabian wood

carving).

Aesthetic inspiration and modernity go hand in hand, in

the elegant Arlequin table multicoloured legs by Marie

Christine and Mario Silva or the fine, smooth sides of the

Beluga bath by Jérémy Bataillou. The new concretes lend

themselves to the inspiration of designers who make the

most of all the characteristics of ultra-high-performance

concretes to conceive new forms and bold, new objects,

and to reinvent the world we live in.

Ultra-high-performance:

the future of concrete?

Ductal® is a high-tech material with an unrivalled combina-

tion of technical properties - ductility, strength and

durability, coupled with aesthetic qualities - resulting from

its specific particle distribution and reinforcement with

organic or metallic fibres incorporated into the concrete.

With a compressive strength four to eight times that of tra-

ditional concrete (130 to 200 MPa), it is ideal for light-

weight, complex architectural structures. The 24 white

concrete shells of the elegant Shawnessy Light Rail Transit

Station in Calgary (Canada) are a mere 2cm thick!

Its ductility gives it significant flexural strength (20 to 40

MPa, compared to 3 to 7 MPa for ordinary concrete) and

enhanced deformation resistance. Low porosity makes

Ductal® more resistant to pollution, severe weather

conditions and extreme temperature variations, giving it

extended durability.

Because it is easy to work with and provides such a smooth

finish, Ductal® is ideal for open work and textural effects

such as the lattice façade created by architect Manuelle

Gautrand -- intended to let light into the Villeneuve d'Ascq

museum.

with JacquesFerrier

Hypergreen aims to make a reality of the

architect's dream -- to "limit the global

impact of buildings". Ecologically friendly

materials and respect for the environment

in day-to-day use are the key concepts

behind this multipurpose tower; to meet

the needs of cities forced by space

constraints to adopt high-rise buildings.

This 246m skyscraper of the future is

distinguished by an outer skin made from

a Ductal® mesh. The density or openness

of the mesh is determined by exposure to

the sun, wind and climate.

On the north side of the building, it allows

sunlight to penetrate, but acts as a

sun-shield on the south side to prevent

over-heating. The mesh also directs air

flows to wind turbines located on the

roof, optimising building ventilation.

Hypergreen uses renewable energy sources

(earth heat exchangers, geothermal heat

pumps, tempered glass, etc.) to produce

most of its energy needs.

Rainwater is collected and filtered for

re-use in plumbing and for the gardens.

The goal is for Hypergreen to meet 70% of all its energy needs

Combining concrete, modern design and

ecology is a dream that Jacques Ferrier

presents to visitors at the exhibition;

encouraging them to share his concerns

and show that solutions exist to meet the

crucial challenge of protecting the planet

and yet still cope with the pressures of

population growth.

in briefA unique material for an exceptionalexhibition

"Béton: étonnez-vous"

(Concrete: be astonished") is an

invitation to explore the heart

of the history of a material so

much part of our everyday life

and yet so little known.

The visitor marvels at a black

ship made of ferro-cement and

dating from 1855, and concrete

replicas of the Venus de Milo

dating from 1878! Models,

documents and slide-shows

bring to life a history studded

with technical landmarks and

groundbreaking constructions;

from Antonio Gaudi's 1905

Casa Mila to the model of

Jacques Ferrier's futuristic

Hypergreen tower. The 500m2

exhibition, clad in a thin, colou-

red mineral skin made from

Ductal®, reveals this revolutiona-

ry material's enormous potential

in terms of performance and

creativity. Display cases feature

jewellery alongside sculptures or

perfume bottles… all made of

concrete! The exhibition also

unveils the very core of the

material itself, its components

and its applications, aided by

clear, simple explanations and

instructive examples.

Exhibition dates

extended to March 2007.

Conservatoire National des

Arts et Métiers

60 rue Réaumur (75003 Paris).

Tuesday - Sunday included,

10 a.m. - 6 p.m.

Tel: 01 53 01 82 51

http://www.betons.arts-et-

metiers.net/main_ie.html

EXHIBITION SPECIAL ISSUE

Interview

A credo that Jacques Ferrier hasput into practice with his designfor the Hypergreen project thatcould become a reality inShanghai, Paris, or any othermetropolis trying to cope withhigh population density while seeking to limit the environmental impact of buildings. Hypergreen is an answer to the question of how to create environmentally sustainable buildings that blendin harmoniously with the urbanlandscape.

"21st centuryarchitecturewill be

or nothing!"environmental

As the exhibition's natural sole partner,the Lafarge Group stressed that the eventshould also highlight the ecological qualities of a material that combinesdurability, strength and economies ofboth materials and energy. A sustainable

development challenge at the very heartof Lafarge's strategy, in order to designnew products and methods of construc-tion which are more environmentallyfriendly.

Concrete: contributing to sustainable development?

Editorial

DR Photothèque Eiffage/Daniel Jamme

DUCTAL_SPECIAL_GB_AF 18/10/06 15:50 Page 1

Research, design and experiment, the key concepts on

which the Musée des Arts et Métiers has founded its

reputation as one of the world's leading technical

museums, are particularly appropriate in defining the his-

tory and the future of concrete. As a research centre with

a mission to instruct, it was only natural that the museum

should focus attention on a material that is so often

stereotyped, despite a history that reveals how successive

strides in invention over the last century have made it a

truly high-tech material.

For Bertrand Lemoine, the exhibition's Scientific Director,

"this event places concrete firmly in the context of a his-

tory closely linked to research, experimentation, and

technological innovation in which designers and engi-

neers come together to roll back the limits of architectu-

re, civil engineering and design. The aim of the exhibition

is to alter the image we have of concrete, astonishing the

visitor by revealing how open it is to invention, and how

it is constantly evolving. The exhibition starts off symboli-

cally with a selection of objects that no one would ever

imagine being made of concrete, then moves on to a

boat (!) before ending at a futuristic tower. The examples

on display reveal all the nobility of concrete and its fan-

tastic creative potential."

How does a new product like Ductal® come into

being?

Léopold Lombard : Aside from Lafarge's commit-

ment to R&D, with over 500 dedicated engineers

and the results they achieve, I am convinced that

Ductal® would not have had the same success had it

not been for the partnerships we have established

with architects. The competition they face for every

new project drives them systematically to seek out

new solutions to help them express their creativity.

Form is always and increasingly dictated by the

material and its performance capacities. And since

we don't build in glass in the same way as we build

in concrete, we industrialists have to be on hand as

early as possible in the creative process to make sure

that the project is "conceived" in concrete. We have

established a relationship built on trust and a convic-

tion that working together gives them the best

chances of winning commissions.

Is this privileged relationship compatible with

your industrial production constraints?

Léopold Lombard : The "Béton: étonnez-vous"

exhibition, which showcases the extraordinary range

of applications for concrete, and in particular the

latest creations using Ductal®, offers a perfect illus-

tration of the spirit behind this partnership between

architects and industry. My role is to accompany

architects step by step through every stage of their

project, to help them overcome any technological

obstacles they may encounter. The spirit behind this

approach has not failed to strike a chord with the

most creative architects, who appreciate working

with a group prepared to enlist all our different skills

-- to work with them on a solution that will meet the

challenges of their creativity. We are very close to a

“bespoke” (customized) service, in view of the fact

that once the research is completed, Ductal® offers

scope for rapid, simple casting and pouring. The

creative thinking of these architects, the quality of

the projects that emerge from this collaboration,

and the reputation they earn, all combine to drive

forward development in step with our industrial

objectives.”

It was French engineer, Bernard Forest de Belidor who gave

concrete its name, derived from the Latin word “concre-

tus”, in 1729. In 1818, Louis Vicat prepared the first

mixture of limestone and clay and heated it to 1200°C.

Fellow Frenchman, François Coignet compacted concrete

and reinforced it with iron bars when building his own

house in 1853. On the other side of the Atlantic, in 1909,

the famous inventor, Thomas Edison built the first cast-

concrete house; the precursor of the prefabricated buil-

ding. After the engineers, it was the architects turn to

adopt concrete; for instance: Anatole de Baudot with the

church of Saint Jean de Montmartre (1903), Antonio Gaudi

in Barcelona, Auguste Perret and then Le Corbusier with

the Villa Savoye in Poissy. Frank Lloyd Wright completed

the Guggenheim Museum in New York in 1959, as Oscar

Niemeyer was starting the construction of Brasilia

Cathedral. Swiss architect Robert Maillart, a virtuoso in

reinforced concrete, designed a total of 47 bridges,

including the 1930 Salginatobel Bridge across the Salgina

Gorge: a span of 90 metres, with not a single pier!

At the same time, research was forging ahead. In 1929,

Eugène Freyssinet invented prestressed concrete. Pier Luigi

Nervi invented “ferro-cement” (a construction method

using steel wires covered with sand and cement plaster),

and built a 12m boat in 1948. Researchers went on to

develop high-performance concrete and then ultra-high-

performance concrete, while architects gave free rein to

their inventiveness. The exhibition includes examples of

fibre-reinforced concrete designed by the talented Lancelot

Coar, and LiTraCon™, a translucent concrete that transmits

light via embedded glass fibres, invented by Hungarian

Aron Losonczi.

solutionsSpecial Edition - October 2006

an exceptional exhibitionrecord

The stuff of inspiration?The number of concrete buildings that have

become landmarks in the history of civilization is

significant. It even includes religious buildings,

where architects have not hesitated to turn to

technology to express a sense of spirituality. As

Le Corbusier was completing his chapel at

Ronchamp in 1955, architect Guillaume Guillet

was beginning work on the church at Royan -

two major examples of contemporary religious

architecture. The chapel at Ronchamp is famous

for its double-shell roof of reinforced concrete -

two membranes each 6cm thick separated by a

gap of 2.26m. Le Corbusier took his inspiration

from a crab shell when designing this roof in the

form of an inverted conch shell, supported by

concrete pillars and beams.

Notre Dame de Royan amazes one with its soa-

ring height and size: 45m long by 22m wide,

with a bell tower 60m high. The roof consists of

a saddle-shaped shell of reinforced concrete

only 8cm thick that covers 100m2 of the nave.

So light is this roof that only thin outer walls are

needed to support it, in a series of thin V-sha-

ped shells using a system designed by the pro-

ject engineer Laffaille for SNCF railway sheds.

An exhibition revealing all the nobility of concrete

Léopold Lombard - Vice-President, Architect Relations

Architect creativity drives industrial innovation

Why is concrete the material of the future?

Paul Acker : Concrete, at 15 billion tonnes, repre-

sents two thirds of all the construction materials

used annually, and twenty times more than metal,

for example. Reserves of limestone, clay and sand

raw materials are the most plentiful around, while

the cost of petroleum-based materials is increa-

sing, so we can reasonably expect concrete to

experience strong growth in applications such as

road building. Moreover, countries like Denmark

and Belgium are already recycling concrete on a

large scale.

In addition, however, high-tech approaches to

designing customized concretes are opening up an

even wider range of opportunities for this 100%

natural material.

In just twenty years, we have progressed from the

high-performance concretes used in projects such

as the Ile de Ré bridge - a great technical and eco-

nomic success - to ultra-high-performance concre-

tes. Today we are achieving compressive strengths

of up to 200 MPa, while also developing casting

fluidity for greater ease of use on site. Ultra-high-

performance concretes contain up to five granular

components and a number of polymers including

the new superplastifiers.

The sheer number of potential components will

increasingly make it possible to produce "customi-

zed" concretes to match the specific mechanical

properties required or meet aesthetic or thermal

insulation constraints. Special software now exists

to optimise formulations and mixtures, incorpora-

ting organic or plant fibres for mechanical

strength, polypropylene fibres for fire-resistance or

polystyrene beads for their insulating properties.

How does concrete rise to the challenge of cutting

energy consumption?

Paul Acker : The key issue is how to reduce energy

consumption in buildings. Increases in calorific

capacity and thermal insulation have a direct

impact on energy consumption for heating. We

are looking at multi-layer structures combining

concrete with other products for optimum thermal

insulation.

Thermal inertia is one advantage of concrete that

could be improved still further by, for example,

embedding beads of phase change materials that

change from liquid to solid state, like those in free-

zer packs.

These offer considerable advantages when there

are significant temperature differentials between

day and night.

Different forms of concrete can be used, some for

building facades to improve thermal insulation,

and others for interior walls for optimum acoustic

performance. Constructors are also demanding

ever greater durability.

The specifications for the Channel Tunnel covered

a period of 120 years!

A history of passionate endeavoursBuilders, architects, engineers and cement manufacturers:

As an architect, Léopold Lombard knows that now, more than ever, architecturaldesigns require strong links between architects and industry R&D. His role at Lafarge isnot about sales but about the need to attentively monitor and listen to architects' aspi-rations in order to help design the materials that will enable them to unleash theircreative energy, whatever the project.

The Romans used to mix lime with volcanic ash, pozzolana, to provide a cement-like set.Although it later disappeared from general use until the dawn of the 19th century, the storyand evolution of concrete is directly tied to the research scientists, engineers and architectsthat have endlessly reinvented it.

Towards customized concrete Two questions for Paul Acker, Scientific Director of the Lafarge Research Centre at L'Isle d'Abeau

The greatest dome in Antiquity,

the “Pantheon” in Rome, is

made - believe it or not - of

concrete! This masterpiece, 43m

in diameter, was built in the 2nd

century. This is the first in a long

line of concrete buildings, as the

material proved that it would

enable man to build ever bigger,

higher, longer, lighter and

stronger structures, due to the

imagination and creativity of

architects, ingenuity of engineers

and the inventiveness of indus-

trialists. In 1930, Italian Pier Luigi

Nervi built one of the biggest

aircraft hangars ever (330m x

130m) and the concrete dome of

the CNIT building in Paris La

Défense, completed in 1968

(covering a 2-hectare area), is

still considered the largest roof in

the world. Meanwhile, the

Water Tower Building in Chicago

pierces the clouds at 261m high

and the Maracaibo Bridge in

Venezuela is the world's longest

concrete bridge at 8km, with

119 spans. Closer to home, the

Millau viaduct (opened in 2004)

is the highest road bridge in the

world, with its concrete piers

soaring to a maximum height of

245m.

Other achievements in concrete

were the two Mulberry harbours

built by the Allies for the

Normandy landings in 1944,

protected by 215 caissons

weighing between 7,000 and

15,000 tonnes -- that had to be

towed across the Channel.

Boldness and innovation are the

keynotes of Bill Price's experi-

mental Pixel Chapel project. His

panels, studded with points of

light from an embedded fibre

optic grid, create a planetarium

effect! But the record for

lightness has to go to the 120m

Seonyu “Footbridge of Peace” in

Seoul, Korea, designed by Rudy

Ricciotti, with a Ductal® deck just

3cm thick!

Ever higher,ever farther


solutionsin brief

The Lafarge- Ductal® newsletter - October 2006

250 years of innovation on displayLongevity or creativity? Symbol of an era,or product of an imagination that knowsno limits? What is the connection bet-ween the Pantheon in Rome, the CNITbuilding in Paris La Défense or theMUCEM building in Marseilles, if not thesame passion for a material capable ofendlessly reinventing itself: concrete? Butthe extraordinary ascension of this "kindof powder which, by nature, produceswonderful results" (Vitruvius, 1st centu-ry) is closely associated with the industrial era. For the past 250 years, thehistory of innovations achieved by architects and engineers working together has been closely associatedwith the history of Lafarge. A partnershipthat, over the past century and a half,has made possible the construction ofbuildings symbolising, each more strongly than the last, progress, urban

development and the towns and cities inwhich we live today. From ferro-cementships to translucent concrete, the exhibition organizers have lined up aseries of surprises and innovations forthe public and industry professionals, toadmire. The exhibit demonstrates justhow much concrete shapes our lives andsurroundings, whether in the form of astructure, façade, jewellery, furniture, oran endless range of other products.A diversity of often little-known applica-tions which, with the arrival of Ductal®, isexpanding at a rate limited only by thecreativity of architects and designers. Inother words, an unlimited one!

Prepare to be astonished!

Jean-François Batoz, Vice-President,Ductal® Development

solutions Special Edition - October 2006





When concrete spells design

"Béton: étonnez-

vous" has more

than one surprise in

store. Incredibly slim

benches stand side

by side with poufs

(ottomans) and an

"Ellen" bookshelf

made from solution-dyed caissons - all creations in Ductal®

by Francesco Passaniti. Concrete also shows its versatility in

the form of street furniture, a bath, a desk, a chair and

even jewellery - in the hands of Patrice Fabre - or a perfu-

me bottle designed by Thierry Bogaert.

Elsewhere, concrete meets transparency with the Ductal®

formwork bench designed by Olivier Chabaud and Laurent

Levêque and made from a slim, flat sheet of open-work

mesh, like the lace-work of a mashrabiya (Arabian wood

carving).

Aesthetic inspiration and modernity go hand in hand, in

the elegant Arlequin table multicoloured legs by Marie

Christine and Mario Silva or the fine, smooth sides of the

Beluga bath by Jérémy Bataillou. The new concretes lend

themselves to the inspiration of designers who make the

most of all the characteristics of ultra-high-performance

concretes to conceive new forms and bold, new objects,

and to reinvent the world we live in.

Ultra-high-performance:

the future of concrete?

Ductal® is a high-tech material with an unrivalled combina-

tion of technical properties - ductility, strength and

durability, coupled with aesthetic qualities - resulting from

its specific particle distribution and reinforcement with

organic or metallic fibres incorporated into the concrete.

With a compressive strength four to eight times that of tra-

ditional concrete (130 to 200 MPa), it is ideal for light-

weight, complex architectural structures. The 24 white

concrete shells of the elegant Shawnessy Light Rail Transit

Station in Calgary (Canada) are a mere 2cm thick!

Its ductility gives it significant flexural strength (20 to 40

MPa, compared to 3 to 7 MPa for ordinary concrete) and

enhanced deformation resistance. Low porosity makes

Ductal® more resistant to pollution, severe weather

conditions and extreme temperature variations, giving it

extended durability.

Because it is easy to work with and provides such a smooth

finish, Ductal® is ideal for open work and textural effects

such as the lattice façade created by architect Manuelle

Gautrand -- intended to let light into the Villeneuve d'Ascq

museum.

with JacquesFerrier

Hypergreen aims to make a reality of the

architect's dream -- to "limit the global

impact of buildings". Ecologically friendly

materials and respect for the environment

in day-to-day use are the key concepts

behind this multipurpose tower; to meet

the needs of cities forced by space

constraints to adopt high-rise buildings.

This 246m skyscraper of the future is

distinguished by an outer skin made from

a Ductal® mesh. The density or openness

of the mesh is determined by exposure to

the sun, wind and climate.

On the north side of the building, it allows

sunlight to penetrate, but acts as a

sun-shield on the south side to prevent

over-heating. The mesh also directs air

flows to wind turbines located on the

roof, optimising building ventilation.

Hypergreen uses renewable energy sources

(earth heat exchangers, geothermal heat

pumps, tempered glass, etc.) to produce

most of its energy needs.

Rainwater is collected and filtered for

re-use in plumbing and for the gardens.

The goal is for Hypergreen to meet 70% of all its energy needs

Combining concrete, modern design and

ecology is a dream that Jacques Ferrier

presents to visitors at the exhibition;

encouraging them to share his concerns

and show that solutions exist to meet the

crucial challenge of protecting the planet

and yet still cope with the pressures of

population growth.

in briefA unique material for an exceptionalexhibition

"Béton: étonnez-vous"

(Concrete: be astonished") is an

invitation to explore the heart

of the history of a material so

much part of our everyday life

and yet so little known.

The visitor marvels at a black

ship made of ferro-cement and

dating from 1855, and concrete

replicas of the Venus de Milo

dating from 1878! Models,

documents and slide-shows

bring to life a history studded

with technical landmarks and

groundbreaking constructions;

from Antonio Gaudi's 1905

Casa Mila to the model of

Jacques Ferrier's futuristic

Hypergreen tower. The 500m2

exhibition, clad in a thin, colou-

red mineral skin made from

Ductal®, reveals this revolutiona-

ry material's enormous potential

in terms of performance and

creativity. Display cases feature

jewellery alongside sculptures or

perfume bottles… all made of

concrete! The exhibition also

unveils the very core of the

material itself, its components

and its applications, aided by

clear, simple explanations and

instructive examples.

Exhibition dates

extended to March 2007.

Conservatoire National des

Arts et Métiers

60 rue Réaumur (75003 Paris).

Tuesday - Sunday included,

10 a.m. - 6 p.m.

Tel: 01 53 01 82 51

http://www.betons.arts-et-

metiers.net/main_ie.html

EXHIBITION SPECIAL ISSUE

Interview

A credo that Jacques Ferrier hasput into practice with his designfor the Hypergreen project thatcould become a reality inShanghai, Paris, or any othermetropolis trying to cope withhigh population density while seeking to limit the environmental impact of buildings. Hypergreen is an answer to the question of how to create environmentally sustainable buildings that blendin harmoniously with the urbanlandscape.

"21st centuryarchitecturewill be

or nothing!"environmental

As the exhibition's natural sole partner,the Lafarge Group stressed that the eventshould also highlight the ecological qualities of a material that combinesdurability, strength and economies ofboth materials and energy. A sustainable

development challenge at the very heartof Lafarge's strategy, in order to designnew products and methods of construc-tion which are more environmentallyfriendly.

Concrete: contributing to sustainable development?

Editorial

DR Photothèque Eiffage/Daniel Jamme


The Clichy municipal swimming pool

was built in 1968 and required

extensive work. The Town Hall opted

for refurbishing including recons-

truction of the south-facing, fully

glazed main facade.

ENIA Architects suggested the instal-

lation of external sunscreens to

control the solar impact and, accor-

dingly, the thermal ambiance in the

pool. This new double skin is made

up of a grid of horizontal and vertical

blads of Ductal®, forming rectangular

modules (L. 2.50 x H. 1 m) mounted

to the existing metal structure.

« Ductal® has structural characteris-

tics that allows us to obtain a very

thin mineral construction - around 4

cm for spans of 2.50 m », points out

Dominique Stoeux, Managing Dire-

ctor of Betsinor, the prefabrication

company in charge of the project.

Not only were the architects able to

take advantage of specific technical

features in order to construct a long-

lasting facade with thin and slender

shapes, they were attracted by the

luminous color range offered by

Ductal®. To Julien Bérujeau, architect

and project manager, « it undersco-

res the lightweight impression of the

grid, suspended in front of the dark

background of the facade. The top

surfaces of some horizontal slats are

lined in red, reflected on the outside

module. The colors are never percei-

ved directly but simply by their

reflection which varies according to

the brightness. The asymmetrical

reflections set off the extreme regu-

larity of the sunscreen ».

solutionseditorialIn brief

The Lafarge Ductal® Newsletter - No. 5 - April 2007

Everyday concrete …The standard manufacturing of design objects, a colorrange kicking off tailor-made creative processes, worksof art fitting in with an institutionalized approach toinnovation and design... Ductal® opens up new horizonsevery day, thanks to you and with your help. It has beendecided to devote this latest issue of Ductal® Solutions tomore concrete applications, bringing ultra-high-perfor-mance concrete into people everydaylife by bringing innew values in terms of elegance, strength, creativenessand invention.

Ductal® symbolizes this breakdown, I almost said "demo-cratization" in design, moving into every area of decora-tion, filling out living areas and appearing as lamps, shel-ves, staircases, armchairs, furniture, etc. Despite thisgreat diversity of applications, we mustn't loose sight ofthe functional features of the product, that overpass allstandard concrete performances, such as lightness, out-standing design, durability, the ideal proof of whichcomes from the recently completed Calgary footbridge.

Jean-François Batoz - Development Director

Owner

Ever-higher with Ductal®

After two years of design and test

work, the first Ductal® spiral staircase

was assembled in the factory belon-

ging to Escaliers Décors, a company

specialized in steel staircases for reno-

vation.

"Although we are using steel we were

particularly attracted by the outstan-

ding potential of Ductal®, especially

for the heart of our trade, decoration,

explains managing director, Pascal

Godineau. "It would be unthinkable

to install a traditional concrete stairca-

se on the parquet floor of a Paris two-

floor apartment. The lightness offered

by Ductal® - up to half the weight -

means that we can move into this

new market with staircases whose ele-

gance, color range and finish presents

new opportunities - in terms of highly

original designs.“

We will be installing a first project in a

private house in Savoy (France) in a

month’s time. Work will be facilitated

by the prefabrication of the parts in

the factory and delivery, almost as a

kit, for assembly on the spot. This is

an undeniable extra advantage for

renovation specialists in buildings that

cannot accommodate a single flight

concrete staircase.

In brief

Clichy-la-Garenne : Regulating the thermalenvironment of the municipal swimming pool

Beno

ît Fo

ugei

rol©


techno

solutionsN° 5 - April 2007

reportpress review

Ductal® versus stainlesssteel?For reasons related to structural

strength and durability, clarifying

troughs in water treatment centers

are traditionally made of stainless

steel. «By meeting the requirements

for durability and lightness, Ductal®

has opened up the way for experi-

mentation», explains Don Zakaria-

sen, Prefabrication Director in

Calgary. «And it is a lot cheaper

than stainless steel».

A new application has been valida-

ted by the Gold Bar water treatment

plant in the city of Edmonton, the

first in the world to use clarifying

troughs made of Ductal®.

The Wapello Bridgewins a PCA award. The Wapello County Mars Hill

Bridge in Iowa, USA, has just car-

ried off the prestigious PCA

2006Concrete Bridge Award. This

biennial competition pays tribute

to excellence in the design and

construction of concrete bridges in

Canada and the United States.

The 2006 program received entries

from 79 candidates, covering a

wide diversity of structural types

and construction methods.

The bridge is a significant break-

through towards the "Bridge of

the Future" with three Ductal®

beams measuring 33 m in length -

that do not have any rebar for

shear stirrups.

Alberta Construction Magazine - Nov/Déc. 2006

The City of Calgary encouragesthe use of innovative materials inits infrastructure projects with aspecial design program motiva-ted by aesthetic challenges, acommitment to incorporatepublic art and the need to copewith varying weather conditions.

The “Glenmore/Legsby Pedes-trian Overpass”, is a 53 m post-tensioned footbridge with a 33.6m drop-in Ductal® “T-section”girder (3.60 m wide, shaped in ashallow parabolic arch) and twocantilevered, high performanceconcrete piers. Crossing an eight-lane urban throughway, it is anattractive, state-of-the-art techni-cal model for structures exposedto tough climates. Constructionof North America’s secondDuctal® footbridge was made

possible by the City of Calgary,architects Cohos Evamy andLafarge’s precast team. Artist Adam Kuby, commissionedby the Department of Transpor-tation through the Public ArtProgram, illuminates the cutting-edge materials and unique engi-neering through interpretive pan-els with integrated words andmanipulated shapes. Pedestriansare made aware of the state-of-the-art engineering and the for-ces at work around them. For information, visit : www.cal-gary.ca/publicart > Projects inProgress > Glenmore/LegsbyPedestrian Overpass.

Technical and logisticaccomplishments beyondknown standardsOnly 1.1 m deep at mid-span, thebeam weighs approximately 100tons. To Erik Pelchat, Lafarge pro-ject manager, « this achievementis exemplary ; it prompted us topush our own solutions to techni-cal and logistical levels thatextend beyond known standards.Because of its size, vertical curveand specific design requirements,purposely avoiding any internaltension in the Ductal® material,the beam’s formwork presented anumber of challenges.

Manufacturing involved the big-gest monolithic casting everaccomplished using Ductal® andrequired 40 m3 of material. Aftercasting, the beam was putthrough heat treatment for 48hours at 90 °C. Load tests wereperformed on 3,1 m long, fullwidth and full depth girder sec-tions. Static and fatigue flexuraltests were performed at theUniversity of Calgary and a loadtest was performed on the full-scale span, prior to shipping tothe site. In addition to the fibermatrix, the beam was post-ten-sioned with two bundles ofstrands and glass fiber reinforcedplastic bars (GFRP) for extra pre-caution.

Logistically, it meant that specificcomponents ; the GFRP bars,stainless steel reinforcement,inserts and post-tensioned hard-ware, all had to be delivered atthe same time and on time. Thefinalized system was transportedto the site via specific routingusing special, heavy haulingequipment. Installation requiredtemporary closure of traffic onone of the busiest roads inCalgary. We managed to installthe 100 ton Ductal® drop-in solu-tion in just eight hours ».

Calgary, Canada takes pride in its cutting-edge, aestheti-cally engaging civic infras-tructure. Thanks to an innovative design program,this is confirmed with completion of a new Ductal®

footbridge that spans 53meters across an eight-laneurban highway. An amazingtechnical and artistic feat !

Civil Engineering - Nov. 2006

What is the future for Befup?This was the question raised by the

latest issue of Béton magazine...

answering "yes" and referring to

the diversity of applications that

construction firms, architects and

engineers are now exploring, to

open up the full scope of the futu-

re in terms of extraordinary achie-

vements.

Concrete - March/April 2007

Glenmore/Legsby footbridge in Calgary

The world's biggest monolithic Ductal®

creates a beautiful footbridge

• Greater structural strength with reduced weight.

• Ultra-fast installation with minimum traffic interruption

• Design allowed for elimination of a central pillar,

enhanced visibility and improved road safety.

• Greater resistance to penetration of chlorides

from bridge deck cleaning and salting during winter months.

• The smooth surface finish meets aesthetic demands.

• Greater durability and reduced maintenance.

Ductal® for the Glenmore/Legsby bridge : an outstanding difference

Bridges and footbridges zoom

The Ductal® color chart : creative diversity

Ductal® is making a centre-stageentrance in Italy, where Il Cantiere, aFiume Veneto Company has decided todedicate a 2000 m2 factory exclusivelyto the production of Ductal® products.Resulting from the particularly creativeassociation of a renowned industry anda designer, won over by the possibilitiesof ultra high-performance concrete, IlCantiere is offering a particularly uniqueproduct range.

“Everything started from a desire tobring concrete and its new propertiesinto areas where it would have beenunthinkable to think of using them ashort time ago“, explains Luigi Rossi,designer at Il Cantiere. “This materialhas become a source of inspiration for arange of decorative wall panels, interiorand outdoor lamps, mantelpiece corni-ces, furniture... The range of possibili-ties opened by the strength, utilizationflexibility and available finish range isparticularly vast". That is why Il Cantiere has decided notto confine its activities to its own pro-duction but proposes making its indus-trial know-how available to anybodywanting to transform ideas into achie-vements.www.ilcantieresrl.it

First standard production of Ductal® objects

An interview with Gerald Carson Project Engineer (Cohos Evamy)

Ductal® can be solid-colored with

unequalled stability. The objecti-

ve of the color chart offered by

Lafarge, designed specifically for

architects and designers, is to pre-

sent the 46 colors derived from

pigments of mineral origin.

Selected exclusively by Lafarge

for their stability, the coloring of

raw materials offer the same

durability as uncolored Ductal®.

Four color ranges, developed

with the support of Christelle

LeDean - coloring specialist provi-

de a starting point for all the

Ductal® projects that creators can

dream up.

First of all, there are the "basics",

the "natural" colors of concrete,

shades of white and grey. The

range extends from the lightest

to the darkest, depending on the

percentage of pigments in the

mass, the primary colors of the

metal oxides: black, red, yellow

for the basic selections, or blue

for the more refined.

The Old Town parts of Nice and

its Mediterranean palette inspire

"southern colors". Utrecht, and

the sky of the Netherlands sug-

gest tones of grey while its brick

facades are evocative of "nor-

thern colors". "Modernists" refer

to the architects and schools

inspired by the Bauhaus and illus-

trate the colorimetric potential of

mineral pigment in Ductal®.

Finally the "Domestics" refer to

the world of the house in delicate

and more sensual hues.

The Color Chart is a working tool

and a source of inspiration in its

own right ; an open door to a

wide range of possibilities in the

world of coloring.

To produce other colors, Lafarge

has developed a color counter-

typing tool capable of producing

a tailor-made color from scans of

almost any hue. It’s an ideal chal-

lenge for the imagination.

What were the challenges facing this construction?Gerald Carson : The main condition wasimposed by the City, who wanted a footbrid-ge that would showcase its innovativeapproach to bridge-building. To an enginee-ring design consultant like myself, it meantjuggling between this specification andinflexible constraints relating to the site, bud-get and lead-time.

How did Ductal® become the solution? Gerald Carson : The City’s innovative designprogram favors innovative materials. Theinitial goal of this project was to build a foot-bridge with an attractive design and a Ductal®

T-section beam that could be set into an arch.

Because of the slenderness and strength offe-red by Ductal®, we were able to work with awide selection of aesthetic possibilities thatwould never have been possible with conven-tional concrete.

What is your commitment within the innovative design program developed for Calgary? Gerald Carson : As far as I know, we are oneof the only engineering consultant firms withan integrated design approach and its ownin-house team of architects. We are nowworking on a second bridge for the City ofCalgary, with the same configuration as the onedeveloped for the Glenmore/Legsby project.

Innovative design program

Bringing together design and innovative materials

Technical Data Sheet

solutions N° 5 - April 2007

Editorial committee: Jean-François Batoz - Mouloud Behloul -Author: Philippe Billon - Credits: Photothèque Lafarge - EscaliersDécors - Benoît Fougeirol - Desing/production: Agence All Write01 53 59 83 83 - Printer: Imprimerie BM

Current affairs

Salon du Meuble 2007 :160 colors and a similar number of graphic compositions As the designer behind many original and timeless works

that have imposed concrete in the world of interior decor,

the Francesco Passaniti workshop is now giving it a new

dimension with the distribution of many of its classics in

Ductal® slabs and wall panels. Available in 160 colors, in plain

or graphic designs with repetitive, structured or abstract pat-

terns, the range of possibilities is now so vast that it is bound

to fulfill the desires of all.

Also on exhibit this year at the latest Salon du Meuble (via

the latest workshop creations) are kitchen countertops, the

Space bed or the surprising homage by Passaniti to Mondrian

with the Ellen bookcase.

Urban Highway is a long quiet river

A showcase for works of art

With conviction that the "banks" of busy

urban highway should be attractive, the

City of Calgary asked artists Violet

Costello and Bob Thomasson to design

artwork for the retaining walls of a busy

eight-lane urban highway. So, in the near

future, drivers will be able to see 144 fish

made of Ductal®, swimming along their

daily route. The project is an aquatic

concept, with waves swarming and trout

jumping out of the water, or simply follo-

wing the flow.

The originality of this giant artwork is

based on the relief and realism, the color

range, the finesse and the flexible cutouts

offered by Ductal®. The superimposition of

the wave and fish patterns presented align-

ment challenges with the panels that found

a natural solution with the use of Ductal®.

“Initially the fish were to be an integral

part of the retaining wall panels” explains

Walter Winkler, Operations Manager -

Lafarge Alberta Precast.

“But we soon realized that it was prefera-

ble to manufacture them separately and

mount on the wall panels afterward.“The

Ductal solution offered faster speed of

construction, optimized use of plant space

and allowed us to meet schedule.

Several prototypes were produced in

order to achieve the effect that the artist

desired - and give Calgary drivers the

impression of the long river their highway

represents.

A nice touch of aquatic serenity!

Dreamt up by Rudy Ricciotti for art dealer

Enrico Navarra, the roof over the art galle-

ry in Muy en Provence represents a new

technological achievement for Ductal®.

Large dark panels with a "stealth" look

will soon cover the entire gallery with a

7.7 m overhang, explains Pierre Palot, in

charge of the project for Bonna Sabla.

Each piece of black metal fiber Ductal®

weighs in at 3 tons and has been given

heat treatment at 90° C.

The structure is extraordinarily light despi-

te the size which required all the skills of

the designer, Romain Ricciotti, bridge buil-

ding engineer, and the know-how of the

Lyon CETE to confirm the numerous

prototype tests performed and find the right

answers for this unusual creative task.

The roof is a world-first, only 3 cm thick at

the edge of the overhang and 40 m wide,

providing an extreme visual contribution

to the landscape.

With its experimental and daring charac-

ter, this structure is a reminder of the fact

that concrete has always been initiated

and supported by "committed" co-opera-

tion between the architect and the engi-

neer.

Lafarge is always ready to provide enthu-

siastic support for this kind of passionate

adventure.

Façade : The shining light of the kindergarten

The fruit of the imagination of Parisian architect Bruno Rollet,

the first facade of bright Ductal® panels will adorn a new kin-

dergarten and nursery in Belleville.

“Prefabricator Jousselin developed the mould base of metha-

crylate so that the Ductal® could be brought to a high gloss

- while taking advantage of the asperities specific to the

material“, explained the architect.

Lastly, the panels measuring 3.5 m x 2.5 m will cover the

650 m2 facade, catching every beam of sunlight in a particu-

larly unique manner.

A sy

nthe

tic p

roje

ct p

rese

ntat

ion

imag

e

in briefin brief

“The material as it has been used on

this project displays every aspect of

its performance in something that

looks like a real choreography…”

The experience of this structural can-

tilever roof is perfectly summed up in

the explanation given by Rudy

Ricciotti, the project’s architect. No

framework despite being 40m by

7.7m and only 3 cm thick, the tech-

nological feat reveals “the pure

expression of the material”. For

Romain Ricciotti, the civil engineer

who did the calculations for this

unconventional aeroplane wing,

“Ductal® makes it possible to dis-

pense with the framework leaving

the designers completely free to

consider new shapes. Here the major

innovation lies in the extreme reduc-

tion of the play in the material,

which with thermal variations has a

total bend of only 4mm.

With the transport and handling

constraints related to such large sec-

tions (3 tonnes each) Ductal® pro-

vides a mechanical optimum that is

close to that of steel structures with

far more conceptual flexibility.”

“This roof, proportioned in relation

to its own weight, wind lift, thermal

expansion, service load and delivered

as it is without needing any water-

proofing, is a world first,” enthuses

Rudy Ricciotti. “And without doubt

the most attractive part is making

use of very high technology that

combines the aeronautic industry

experience for the moulds design,

very specialised casting calculations

for monitoring the metal fibres rein-

forcement in the distribution volume

and in the final analysis when

making use of it, a technique that

continues to employ the traditional

skills of the trade. Ultra-high perfor-

mance concretes have definitely

opened up a new era.”

solutionseditorial

The Lafarge Ductal® newsletter - N° 6 - December 2007

For a structural designA footpath like a flying carpet, a staircase in space, asuspended roof - the latest architects’ designs continual-ly reveal more of Ductal®’s structural potential.Its capacities continue to be enhanced in the newapproaches to progress and design. Supported by someof the great names in architecture, Ductal® can be aimazingly shaped, designed and modulated in all thesestructures. A wide range of applications in which ductili-

ty, mechanical resistance and durability are tested.Achievements that illustrate the new symbiosis thatDuctal® allows between imagination and technical skill inorder to combine proportioning and finesse or one-offpieces and mass production - as Rudy Ricciotti predicts,it has opened up “a new era.”

Jean-François Batoz – Director of Development

As a specialist in engineering, proto-

typing and composite technical

research, Cogitech is active in many

business sectors such as: indoor and

urban furniture, jewellery and cars.

This dynamic company has enabled

Lafarge to develop several innovative

methods of employing Ductal®, like the

amazing spiral staircase designed by

Escaliers Décors.

“Our approach is to transfer skills,”

explains its director, Sylvain Quidant.

“Going further than the traditional

research departments, our workshop

can produce casts and short runs, but

the objective is to design production

solutions for manufacturers.

Obviously our team‘s experience and

the diversity of their expertise benefits

to all our clients.

The know-how we have acquired in

producing decorative furniture with

complex methods of assembly and

shapes can also be transferred to

numerous industrial and architectural

applications.”

COGITECH is now continuing to devel

op the use of Ductal® and is exploiting

the technical and artistic qualities that

allow it to be used in conjunction with

other materials.

A new era


Cogitech“We are just beginningto exploit Ductal®’spotential“

techno

Rudy Ricciottifor MaisonNavarra:

The elegant marriage of PEFC cer-

tified wood and Ductal®, signed

by the designer Paul Gaspard, for

the GASPARD label.

solutionsN° 6 - Décembre 2007

reportPress review

Innovation award for awastewater treatmentplant In Canada, the City of Edmonton’s

Gold Bar Wastewater Treatment

Plant (with 192 Ductal® clarifier

troughs) has won a prestigious PCI

(Precast/Prestressed Concrete

Institute) “Harry H. Edwards

Industry Advancement Award”.

The award recognizes the materi-

al’s superior performance in rela-

tion to its durability and light-

weight design, as well as its ability

to provide a cost effective solution.

Even more refined…Ductal® combines utility, safety

and aesthetics with a new range

of urban furniture (shaped like

commas), created by Francesco

Passaniti. These unique furnis-

hings provide attractive barriers

that prevent vehicles from ente-

ring off-limit areas and protect

pedestrians against unfortunate

accidents.”

Ascent Fall 2007

What was your first aim for this

cultural project?

Emmanuel Combarel : The collec-

tion is on display in the villa Greiner, a

late 19th century residence situated

in the German quarter of Strasbourg.

The main challenge was to design suita-

ble access for people with restricted

mobility without emphasizing any

discriminatory aspect. We thought

about creating a gently sloping path-

way in the small garden, designed to

lead to the exhibition rooms. We

wanted to make the pathway an

introduction with a sinuous and amus-

ing approach that enabled all visitors,

whoever they may be, to have easy

and user friendly access to the building

as if on a flying carpet. Which

explains all the difficulties the project

presented us with! It was therefore

essential to go for a material that was

no more than 2 cm thick overall and

which could be easily modulated

given the ramp’s geometric complexity.

Ductal® stood out. Mechanical resi-

stance, finesse, specific elements…

everything fulfilled our goals.

What were the constraints in rela-

tion to its use and in the end what

did Ductal® bring to the museum’s

project?

Emmanuel Combarel : At the start

the biggest problem was to draw-up

3D sections in the shape of a helix to

create the alternating curves. But

there were other constraints, such as

the 4% limit for a wheelchair ramp

and 2% for the slants. The 250 m2

gardens were therefore used to the

maximum to make a ramp that is

49m long made up of 32 modules

with very gentle curves.

THE CULTURAL SINGULARITY

Ductal® has therefore made it possi-

ble to design an extremely thin foot-

path (25mm) which is finally what

gives us the strange impression of

seeing people in a state of levitation

as it disappears into the vegetation.

Furthermore, from a “plastic” view-

point, it pleased us to combine a

material like Ductal® with the cultural

aspects of a 19th century style build-

ing. The concrete pathway offers a

different interpretation, an open and

unusual progression. The occasional

modifications we have made have

enabled us to it give this museum an

essential dynamic… just like the inter-

national dimension of this creative

space that will become a cultural

flagship for the city.

A great tribute to the artist and illustrator Tomi Ungerer, the Centre National de l’Illustrationhas opened its doors in the heart of the city of Strasbourg in Eastern France. In an excep-tional architectural environment, Emmanuel Combarel and Dominique Marrec designed aremarkable sinuous footpath using Ductal®. Following completion of the bus station at Thiais, the ECDM agency again used Ductal®, thistime for a visitors’ footpath with the feel of a flying carpet that marks its cultural singulari-ty. Interview with Emmanuel Combarel.

Today’s architecture July / August 2007

The first building entirelycovered in Ductal® hitsthe front pagesCovered with a double skin of

Ductal®, the new RATP (Paris

urban bus and rail network) bus

station in Thiais (France)

demonstrates amazing, innova-

tive modernism. Well received by

the press, this unique building

appears to be a wave coming

out of a Ductal® slab.

Le Moniteur – Juillet 2007

Bétons – Sept./Oct. 2007

Les Echos – Juillet 2007

Le Point – Juillet 2007

Tomi Ungerer Centre National de l’Illustration

Flying carpet for people with reduced mobility

structures zoom

How are Ductal®’s aesthetic properties preserved?

Situated in the heart of the Canadian

Rockies for a hundred years, the Lafarge

cement plant in Exshaw, Alberta has built a

solid reputation based on technological

know-how. It is a position that has enabled

it to become one of the most efficient and

cost effective plants in the world; supplying

the Canadian and US West with much need-

ed cement, thereby ensuring continued

growth and prosperity in the years ahead.

Recently, a special event was held at the

plant to dedicate a new centennial monu-

ment to the thousands of employees, their

families and the community - who played

such an important part in its history.

Evoking a modern, urban landscape, this

unique work by artists, Michele and Andrew

Mitchell of Edmonton, Alberta, places the

plant in the future by using a combination of

durable Lafarge materials such as Ductal®

and precast concrete (produced by Lafarge’s

Alberta Precast team).

Aptly named “Enduring”, this legacy project

was inaugurated by Alan Kreisberg,

Western Cement Region President, in cele-

bration of 100 years of commitment to

excellence.

A century oftechnology

The outstanding performances of

Ductal® may often lead users to

forget that it is a cement based

material which, by essence, is sensi-

tive to water, despite its extremely

low porosity. The phenomenon is

limited to the very near surface (at

the micronic scale) but requires

treatment to provide surface spe-

cific properties that avoid staining

and efflorescence.

Protection is even more demand-

ing in terms of perfection given

that Ductal® has a very high densi-

ty. The Ductal® development team

has established 2 classes of product

that enable it to be used for all

kinds of applications, particularly

the aesthetic ones that this ultra-

high performance concrete inspi-

res. The first class of product is

more particularly destined for out-

door applications (façades, urban

furniture etc), when exposed to

the rain are subject to efflorescence.

Coatings that are permeable to air

and water have been perfected to

protect the surface while letting

the material breath.

The second class of product applies

to all indoor objects, particularly

those exposed to household and

food related attacks (tables, coun-

tertops etc). It is a 100% stain re

sistant anti UV coating that has

been especially developed for

Ductal®. It makes the surface non

sensitive to water while retaining

the aesthetic properties of the

material and notably the unique

surface appearance and tactile sen-

sitivity that contributes to the

attractiveness of Ductal®.

As a leader in the British market, Lafarge

Cement UK has set up its new head office in

the city of Birmingham, in the centre of the

United Kingdom. The choice of location

reflects a desire not only to be at the centre of

the national Lafarge network of cement

works and supply centres but also to be close

to the major transport routes, notably rail and

air with Birmingham International Airport.

The new premises have been designed with the

idea of presenting Lafarge products and demon-

strating both the durability and the low energy

consumption that these materials favour.

The building has a concrete framework based on

innovative solutions through the use of advanced

concrete such as Agilia® which allows to realise

large concrete ceilings in situ.

The great potential of these products has been

exploited in order to optimise concrete’s inherent

thermal inertia properties, store energy and reduce

the heating and air conditioning requirements. The

consequence is a significant reduction in both op-

erating costs and carbon emissions.

However, without doubt one of the most remarka-

ble parts of this new head office is the huge stair-

way that rises up out of the central hall. The refine-

ment of the Ductal® steps and landings gives it an

elegance that appears to be directly related to the

apparent state of weightlessness and lightness that

Ductal® permits. Making the most of the high resis-

tance provided by this ultra-high performance

fibre reinforced concrete, the architects Webb Gray

and Vincent and Goring have designed the stair-

way with a refinement that would never have been

possible with conventional concrete.

This is clearly a showcase project that symbolizes

the association between the architects’ creativity,

the performance of the materials developed by

Lafarge and the know-how and competence of the

pre casters, such as Bonna Sabla/J. Poussard,

which supplied the Ductal elements.

Birmingham

A huge stairway in space

Technical file

solutions N° 6 - December 2007

Editorial team : Jean-François Batoz - Mouloud Behloul - LisaBirnie - Anne-Sophie Fenart - Editor : Philippe Billon - Credits :Lafarge photo library - Escaliers Décors - Benoit Fougeirol©

Design / Production : All Write agency 01 53 59 83 83Imprimerie BM - Allo Lafarge : 0 820 385 385

Lighting newsJapan lands on Ductal®

Tokyo’s Haneda Airport is the 4th largest airport in the world (in

terms of passenger numbers) and, with a take-off every two

minutes, it has reached full capacity on its three runways. The

construction of a fourth runway will make it possible to open up

new international connections for the capital. Guaranteeing a

20% increase in traffic, this new runway was seriously delayed

by… the local fishermen as it is directly built over their fishing

area. Emerging from the sea, an ultra modern pier on sub-

merged piles will be entirely covered with Ductal slabs fixed on

steel girders. Given not only the economic stakes but also those

involved in building this technological feat, the engineers

obviously set the requirements very high in terms of both the

durability and resistance of the materials and the low mainte-

nance costs.

Resistance to freezing, the degree of impermeability, the capaci-

ty to resist salt abrasion, as well as the lightness of the materials

shaping the slabs were the criteria that led to the choice of an

ultra-high performance concrete. To meet the challenge of a

daily production of concrete that will allow the pier to see the

light of day before the end of 2009, the companies Taiheiyo

Ciment and Taisei, licensed by Lafarge, undertook to supply the

airport site with Ductal® for the next two years. 7,000 blocks of

UFC pre-stressed concrete will be precasted in a specific plant

nearby the jobsite i.e. 24,000 m3, making it the largest project

in the world in relation to the surface area and the technical

constraints. A project to watch !

Nessie receives the 2007 design award

Effervescent industrial furniture!

Designed by the Scottish designer Neil

Poulton and developed by Atelier SEDAP,

Nessie, the new range of outdoor lighting

in Ductal®, has been directly inspired by

the surreal shape of the Loch Ness mon-

ster that is dear to the designer’s

heart. Pure lines of a long neck

emerging from nowhere and

plunging back down into the

lake, the perfect curve of a glimp-

sed back, each light combines the

latest developments in two high

tech fields: Ductal® for the struc-

ture and LEDs, high power Luxeon

K2 for the light source. A real outdoor sculp-

ture, Nessie makes ideal use of the material

developed by Lafarge to stretch, bend, curve

and espouse the designer’s desires.

The quality of the finishes is the hallmark

of Atelier SEDAP which for 25 years has

been specialising in high precision casting.

The Nessie collection is the final outcome

of all its know-how. The coherence be-

tween two high tech solutions, one ex-

tremely resistant to all outside attacks and

the other providing constant

lighting and durability (50,000

hours) will attract private indi-

viduals, demanding hoteliers

and professionals in distribu-

tion that are looking for a desi-

gner, economic and long last-

ing lighting solution. Indeed,

the range has already con-

vinced the APCI (Agence pour la

Promotion de la Création Industrielle) jury

which presented it with its 2007 design

award in mid October. The Nessie collection

is available in two colors : charcoal or sand.

For further information : www.sedap.com

Metal chairs, steel desks, concrete

tables… industrial furniture is very fashio-

nable today. For example, Tolix’s timeless

1930s “A chair” design is a roaring suc-

cess once again. Today the famous name,

the undisputed specialist in hot galvanised

steel furniture, has reinvented outdoor

furniture to be more in tune with current

trends. This time it is combined with

Ductal® to overcome the technical cons-

traints of sheet metal that is too thin to be

suitable for the tops of outdoor tables.

Employing this process expertise, Tolix has

adapted to this new material and has

created its own casting workshop. In the

end, with its mechanical resistance but

above all its ductility, Ductal® makes it pos-

sible to produce outdoor or indoor tables

on which prints and optic fibres work in

different ways to enliven the sheet metal.

A very high-end market range where the

visual impression and the feel of Ductal®

are fully exploited.

Created by the craftsmen who

adore the changes taking place

with concrete, Absolut Béton want-

ed to use all Ductal®’s technical

capacities.

Top kitchen specialists, they design

pieces either made to measure or

using existing moulds that all present their very own patina and

personality. “Because that is the magic of the material that

stands out from the often impersonal work surfaces,” explains

Stéphan Bruno, managing director, “to appear as a unique and

living sculpture even when produced semi industrially.”

One of the major advantages is that it can cope with anything

from manufacturing to fitting. And even if necessary the layout

plan for concrete tiles, which are the latest thing from the com-

pany. Some magnificent slabs that give a kitchen its particular

hallmark as no other decorative element can. For further infor-

mation : www.absolutbeton.fr

Absolut Béton : Unique Ductal® tilesfor unique kitchens

Ductal® was used in an innovative joint solution, poured on site for a bridge superstructure / pre-cast deck system. The exceptional combination

of the properties of the material, in association with the use of pre-cast deck sections gave the engineers the chance to design optimum solutions for bridge construction.In 2004, the Ontario Ministry of Transport (MTO) deployed a new solution to replace the decks of road bridges in a deteriorated condition. The solution consisted in using pre-cast deck sections (strengthened with glass fiber-reinforced plastic) and concrete approach slabs. The Ductal® poured on site was then used to seal the joints and ensure the continuity of the deck segments. This new solution was first implemented on a highway bridge spanning a CNR national railway line in Rainy Lake, near Fort Francis, Ontario.The project demonstrated seve-ral direct advantages of using a

Ductal® solution: reduced size and complexity of the joint, greater tole-rance, reduced on-site risk and very fast construction. Amongst the indi-rect advantages: greater durability, less maintenance, extended lifespan and overall size savings. Through its design, testing and construction, this important project secured a pre-cast bridge deck with a 200 mm joint. By way of comparison, a conventio-nal design requires a 600 mm-wide joint. What is more, the pre-cast deck system (manufactured by TeraNorth Construction & Engineering) enabled the bridge to be reopened to traffic in only 48 hours.After the Rainy Lake project was successfully completed, the Ontario Transport Ministry approved three additional projects for joints on other bridges in the Province. Two were

completed in 2007, one in Sunshine Creek by L.H. North General Contractors and the other in Current River by Nor Eng Construction & Engineering. The third project, in Hawk Lake, will be completed this year by Carillian Construction. After these successful projects, the Ductal® team is currently working with the Transport Service departments in the states of Florida, Virginia, Iowa and New York, to use Ductal® joints right across pre-cast bridge deck segments.

solutionséditorial

techno

Mesh on showWhether for its structural, de-corative, technical, or protective qualities Ductal® concrete lattice work is now highly popular. Its exceptional properties mean that architects are now employing this material on scales that have never been seen before. Teaming up with engineers and designers, they are now able to give a free hand to their creativity, developing panels that are bigger, thinner and more technical. Applications include im-proved light filtration, resistance to climatic effects, a protective dou-ble skin, decorative covering, and vertical landscapes.A Ductal® Solutions production which perfectly blends the tech-nical properties of this exceptional material and the creative talent of our clients.Jean-François Batoz - Director of Development

Ductal® joints: Set in 48 hours for bridges in Canada

www.ductal-lafarge.com Lafarge Ductal® newsletter – N° 7 – July 2008

Gold Bar, a star plantIn Edmonton, Canada, the Gold Bar wastewater treatment plant is still under the spotlight.The innovative project it repre-sents is gripping the attention of the media, but especially PCI journal, where it was featured on the cover and the subject of a 17-page article.

Environnement Mag – March 08.

Ductal® breaker for thermal bridges Improving insulation by redu-cing thermal bridges is a major challenge in construction with the new regulations coming on stream in France. Lafarge’s Ruptal solution consists of pla-cing a new Ductal® section at the end of floor slabs. An idea developed with the support of ADEME, the French environ-mental and energy manage-ment authority.

Beaux Arts – May 08

Inspiral inspirationA great many new architectural projects will soon grow up out of the ground as if pulled out by designers with a love for twists, turns and torsions. Only grea-ter computing power and the constant innovations in concrete products such as Ductal® let these buildings grow upwards and outwards.

Maison & Travaux – Jan-Feb 08

Lace? Crocodile skin?No, concrete!The new slabs produced by Francesco Passaniti’s workshop carry increasingly original desi-gns in concrete: lace-like cut-outs or polished, stamped lizard skin, you’ve got to touch it to believe it!

press review

PCI Journal – Nov/Dec 07

Water World – March 08

Construction Canada – March 08

solutionsN°7 - Juillet 2008

dossier

« For this project, adjacent to presti-gious buildings such as the National Library or the Paris Val-de-Seine School of Architecture, a foliage covering was requested, which is very much in vogue at the moment » explains Marie-Hélène Badia. « We wanted something timeless, even a step up from the vegetation wall. It seemed artificial to plant at great expense. Finding our own way, wor-king the vegetation theme in an architectural sense seemed to be more sensible, and represented a challenge that interested us. For our clients, Opac and Semapa, the ren-dering had to be homogenous. The fine texture and lightweight design of Ductal® made it the most suitable material to produce the 44 cut-out panels, which were attached to 3 sides of the building, up to the 8th floor. Each panel is 6.60 m high and 2.30 m wide. »

Freedom of residents « The panels are not just for deco-rative effect, they will be supports for foliage, with pre-planted boxes containing four different types of creeping ivy, » says their desi-gner. « It was therefore important to manufacture them in a mineral material, so that the plants can fas-ten on well. However, as each panel covered 15 m², with 70% of empty space, producing such a structure in reinforced concrete would simply have been impossible. » « Just the production of the panel mould took a thousand hours of work!” explains Jean-Yves Jousselin, manager of the company where the panels were produced. « The 44 pieces were poured in this single, complex-form mould, with thicknes-ses ranging from 7 to 9 cm. Ductal® offered another advantage for this project: its lightness. Each element

weighs 1.8 tonnes, and once fixed to the balcony railings, the overall weight does not exceed the limita-tions inherent to the construction project. » To design the panels, the architects called in an artist with whom they had already worked on other pro-jects, Elisabeth Guilhem. She is a painter whose foliage work blends imagination and graphic represen-tation. She also chose the color of the trellis. The plant pots included in the structures were selected and planted by the landscape gardener Jean-Michel Rameau, but residents of the building may add their own creations.These panels are where Ductal® meets vegetation and creation, so keep an eye on the trellis, especially in spring…

For the renovation of the ZAC Paris Rive Gau-che (Paris Left Bank Desi-gnated Development Area), the architects Badia-Berger have desi-gned several residential buildings that catch the eye: a green trellis climbs up the building walls to create an astonishing vertical landscape.

ZAC Paris Rive Gauche

Mineral foliage for vertical landscape

résille zoom

« Located in a sensitive neighborhood, the cultural center will host a number of acti-vities, including art exhibitions, » explains Philippe Gibert.« Our mission was therefore to work on exposure to the sun and interior lighting, while protecting the picture windows. We also wanted the building to fit in well with the specific mineral features of its surroun-ding area. The fine, lightweight design of Ductal® panels, along with the robustness of the material enabled us to fulfill all these

requirements. » For Dominique Novac, project engineer at Betsinor, manufacturer of the pre-cast sections used on this pro-ject: « Although some perforations rea-ched 6.5 cm in diameter, with the constant performance of the material we were able to produce panels of 2 m x 4.5 m, but only 5 cm thick, to cover the 330 m² of façade and respect all the requirements of weight, transparency and protection expressed by the project owner. »

It is no surprise that the structural and architectonic characteristics of Ductal® are leading architects to design self-stabilizing external lattice work. For the design of the Hypergreen ecological tower, we wor-ked with Jacques Ferrier to design the exterior enve-lope, in the form of a structural latticework with an elliptical base in Ductal®. We dimensioned the exter-nal structure arrangement. The idea was to ensure that the tower is braced only by the lattice work, and that wind transits efficiently through the peripheral structure. This is made possible by the inertial proper-ties of the elliptical section, which concentrates the rigid sections where they are most efficient. Its own weight is transferred to lower levels via a succession of vertical posts. The basic pattern of the lattice is a non-planar cross on average 14 m high and 8 m wide, itself composed of four plane-parallel arms, with sec-tions that gradually decrease in size in families from 90 cm to 40 cm wide.The elements are assembled using a non-centered vertical post-constraint. Due to its compression-resis-tance properties exceeding 150 Mpa, Ductal® resists greater axial loads from pressure on upper strands than standard concrete, thereby enabling the sections to be significantly thinner.Apart from the continuity of the elements, this solu-tion also counterbalances momentum inherent to the

non-planar configuration of the standard X shape. Effectively, and especially lower down the tower, where the downwards pressure of loads requires axial efforts close to a megatonne, the significant geome-trical rupture leads to the composed flexure section supporting a momentum of close to 350 t.m. Pre-cast encircling hoops also in Ductal® assist in the absorp-tion of this momentum in the lower parts of the tower, while at the tower’s highest point, the elastic equivalent resistance of Ductal®, in the region of 40 Mpa, allows us to avoid use of pre-stressing.Manual analysis was followed by digital simulations using the SOFISTIK software, taking into account the pre-stressing losses related to cable friction in the sheaths, the effects of the phasing of the construc-tion, and of long-term shrinkage and creep.The main difficulty concerning this solution comes from the production of a skeletal structure, part of which is outside and therefore exposed to major dif-ferential thermal constraints.On this project also, the connection of the lattice to the internal slab is the critical point in the construction design.

Dominique CORVEZ and Jean-Marc WEILL, C&EEngineering

At the heart of the urban renovation project in Sedan, the cultural center is set to become the main feature of the entrance to the town. The architect Philippe Gibert opted to create a strong identity by covering the facades with per-forated Ductal® panels. The panels provide natural light on the inside and protect the picture windows from external aggressions.

Sedan Cultural Center

Remarkable Identity

technical file

Self-stabilizing exterior lattice work: the Ductal® solution

To celebrate its tenth birthday, the Stade de France invited Andrée Putman and her agency to renovate the 800 meters of corridors around the private boxes, a lobby and 14 recep-tion rooms. The area surrounding the boxes is decorated in cool, chic shades, avoiding decorative overload with very ele-gant sobriety, apt to charm VIPs using the reception rooms. Having chosen to dress the walls in synthetic leather, the Andrée Putman agency needed a facing for the protective panels on interior concourse that provided continuity but which provided much greater protection. The solution pro-posed by a young Toulouse-based design office ‘Conjugaison création et agencement,” specialists in concrete, won the day: Ductal® panels imitating leather to perfection, in tones defined by Andrée Putman to be in harmony with the recep-tion rooms. 340 panels, 1.70 m by 1 m and 12 mm thick, were produced in close collaboration with Pividal, the manu-facturer, based on a texture thought up by François-Charles Génolini, the creator of the Conjugaison agency.

Solus Décor designs and manufactures hand cast concrete fireplace surrounds, concrete tiles and site furnishings. This spring, Solus launched a new line of Ductal® planters, vessels and site fur-nishings under the banner “Solus Outdoor”. This line is highlighted by the Grate Bench, a 2007 selection for New York’s Haute Green; “the best in sustainable design for the contemporary home”. Solus co-owner and creative director, Khai Foo, says “we have been creating high end precast concrete decor for over ten years and added Ductal® pro-ducts to our collection over the last three. Ductal®’s incredible strength and flowa-bility has allowed us to successfully rea-lize designs that we previously couldn’t even attempt. Its exceptional durability and hardened qualities make it the ideal material for our line of premium, modern outdoor products.”

Szolyd Development Corporation pro-vides innovative design solutions for hard-surface architectural features and furnishings. With ultra-high performance Ductal® products, Szolyd offers design flexibility, durability and practicality; an ideal choice for the manufacture of beautiful sinks, countertops, fireplaces and exterior cladding projects. According to Szolyd owner, Nolan Mayrhofer, “Ductal® offers an amazing addition to the materials we work with. It allows us to create products that were previously inconceivable. As we explore the flexibility that Ductal® allows, we notice a new level of creativity in the projects our clients bring to us. We know we have only begun to scratch the surface of its potential and realize that its applications are limited only by our imaginations.”

The architectural design was the work of Gensler and engineering that of Walter P. Moore staff. The Z-shaped steps in Ductal® have a breadth of 2.21 m and are 2.5 cm thick. Fitted with Ductal® stiffe-ners, these steps offer compression resis-tance of 20,000 psi. They have a particular texture, obtained through the application of textiles to the mould, thereby procuring a non-slip finish. Manufactured by Lafarge Precast, Winnipeg, Canada, and installed by D.E Harvey Builders, the steps are connected by vertical steel bars that are connected to make a handrail. The whole staircase structure weighs 6 tonnes and is hung on a cantilever from a « suspended » beam, independent of the lower landing. In the lower section of the staircase, tuned mass dampers (TMD) have been installed to absorb vibrations. The structure is also fitted with sensors

to capture overtaking and accelerations. A wireless connection to a computer and a plasma screen nearby enable real-time visualization of these parameters.

Ideal for restructuring projects or for high-rise construction, the new Ductal® technical floors designed by BONNA SABLA, part of the CONSOLIS group, represent a major advance in High Environmental French Standard (HQE®) construction. Besides the mechanical performance characteristics provided by Ductal® material, fire resistance (classified M0), lightwei-ght design (14 Kg per 60 x 60 cm slab at 14 mm thickness) and water resistance, CIMBURO is compliant with class 1 resistance requirements defined by the EN 12 825 standard and also has “HQE®“ performances that offer a clear advan-tage over a classic reinforced concrete solution. The amount of extracted raw materials has been divided by 1.3, primary energy consumption divided by 2.1, CO2 emissions divided by 2.4, GWP divided by 2.1. Even the pallet-stacking system was thought through to reduce on-site packaging, thereby improving the installation process of the technical floor.A 30% faster laying time, cable exits possible every 60 cm, flooring that doesn’t wobble, greater room height… CIMBURO offers some very convincing benefits. For full information: www.bonnassabla.com

decoration news

CIMBURO: HEQ technical flooring, classified M0

Concrete decoration: leather for the “Stade de France“ At Design Northwest, Western Canada’s largest conference and exhibition

for architecture and interior design, two booths showcased a variety of uni-que, attractive Ductal® décorative products. Solus Décor of Vancouver, (BC) featured Ductal® benches, floor tiles and planters, while Szolyd Development Corporation of Victoria, (BC) featured Ductal® tables, floor tiles, an architec-tural column cover, a chandelier and a textured wall panel (with integrated waterfall)!

For its head office, Walter P. Moore and Associates Inc. designed an original staircase built using Ductal®, based on finite element modeling using the SAP 2000 software.

Ductal® Décor at Design Northwest

6 tonnes on a cantilever

solutions N° 7 - July 2008

Editorial team: Jean-François Batoz - Laurence Jacques -Lisa Birnie - Anne-Sophie Fenart - Author: Philippe BillonCredits: Lafarge photo library – Design/production: Agence AllWrite - 01 53 59 83 83 Printing: Imprimerie BM -Allo Lafarge: 0 820 385 385

Pont du Diable footbridge Architect: Rudy Ricciotti

DUCTAL® SoLUTionS i mArCh 2009 i 1

SolutionsLafarge DuctaL® newsLetter - March 2009 - n°8

Ductal® in evidence

Over the years, architects, engineers and pre-casters have experimented with the capabilities of Ductal®, becoming more precise and crea-tive with each new experience. More than any other past issue, this edition of Ductal® Solutions reveals this spirit of research and innovation. A footbridge in France, four bridges in North America and an airport runway in Japan; all demonstrate the structural performances of this revolutionary concrete, continuing to validate the

material’s superior durability, strength and aes-thetic properties. Together, these accomplish-ments will lead us to a future in which Ductal® will become the material of choice for builders of remarkable structures that are durable, attractive and economically viable.

Jean-François BatozDuctal® Development DirectorPrecast Marketing Director

EDiToriAL

ConTEnTS

PAGES 2 - 5 i STrUCTUrES • Haneda: Blurring the

borders between sea and sky

• Building bridges• Pont du Diable

footbridge

PAGE 6 irESTorATion• Cladding work in

Ductal®

PAGE 7 i 7 i TEChnoLoGY• How to master

complex structures in Ductal® ?

• The complete Ductal® kitchen

PAGE 8 i DESiGn• Fire objects by Ora-Ïto

and Climart • Taporo : creative

freedom• Ductal® lights up

STRUCTURES

The unusual feature of the new runway at Japan’s Haneda Airport, is that it is built on the sea. The pier providing the base for the fourth runway, built exclusively for international flights, is made of Ductal® slabs secured onto steel girders. To understand the scale of the project, we spoke to Akio Otake, Vice Project Manager for construction firm Taisei Corporation and Akihiko Kodama, Manager of Taiheiyo Cement Corporation (Ductal® supplier in Japan).

Haneda Airport (Tokyo)Blurring the borders between sea and sky

What are the issues at stake in this project?

Akio Otake: By the end of 2010, Haneda will boast a new take-off and landing runway, emerging out of the sea. The pier will stretch out over a massive 520,000 sq m area over the sea, and will feature two structures: an under-water part, consisting of steel pillars and their coatings, going down to a depth of 70 m, and a concrete area of 192,000 sq m secured onto steel girders.

The key issues specified by the engineers for this project are durability, strength and low maintenance costs. Ductal® was selected for its salt resistance (a hundred time superior to an ordinary concrete) and a very low permeability coefficient, far exceeding the values for ordi-nary concrete. The cement company Taiheiyo undertook to supply the airport construction site with Ductal® at an extremely high pace.

The new runway for international flights:520,000 sq m over the sea

What is the current status of this project ?

Akihiko Kodama: The Ministry of Land, Infra-structure and Transport recently announced that the new runway for international flights would be in service by October 2010.

The supply of Ductal® slabs, to form the whole area surrounding the runway itself, is a ma-jor challenge for our Ductal® business. We had to produce 1,100 m3 of Ductal® every month – imagine the scale of the undertak-ing! We will complete the manufacture of the Ductal® slabs by August 2009. Out of the 6,139 slabs required, 3,000 have already been produced.

We have faced a whole range of new challenges, with regard to the scale of the project, securing the raw materials, producing the premix and transporting the materials. However, we have found the right answers for all the technical issues, enabling us to acquire very extensive experience.

What features does Ductal® have that makes it particularly well-suited to this type of con-struction?

Akihiko Kodama: Costs are significantly re-duced for this unprecedented structure due to the durability and surprisingly lightweight design of the Ductal® slabs. Given the charac-teristics of the material, the weight of the slabs can be reduced, as can the cost of the steel casing and the piles.

Akio Otake: Many studies were carried out in order to reach the conclusion that Ductal® was the most reliable solution, with respect to the specific nature of the site and the scale of the project. This product, more than any other, also ensures the highest level of homogeneity across such a large number of slabs. Its du-rability guarantees low maintenance costs over the long term.

2 i mArCh 2009 i DUCTAL® SoLUTionS

Country Hills Pedestrian OverpassAlberta (Canada)

Cat Point Creek BridgeVirginia (United States)

The Jakway Park Bridge in Buchanan Coun-ty, Iowa has three, 51-ft Ductal® pi-girders (produced by Lafarge Precast/Winnipeg). De-signed by the Office of Bridges and Structures at the Iowa Department of Transportation and the Bridge Engineering Center at Iowa State University, it is the first highway bridge in North America built with a new generation of Ductal® pi-girders, the first North American highway bridge project to incorporate batching of Ductal® in a ready-mix truck, and the second highway bridge project in Iowa and North America to be built with UHPC girders.

In Kenora, Ontario, the Hawk Lake Bridge uti-lized the Ductal® “JS1000” Joint Fill solution. The photo at left shows the deck panel joints being covered after a Ductal® pour to provide curing. By utilizing the material’s superior prop-erties in conjunction with precast deck pan-els, engineers can create optimized solutions for advanced precast bridge deck systems with simplified fabrication and installation processes. This solution paves the way for fu-ture full-depth waffle deck panels with Ductal® field cast joints!

In Calgary, Alberta the Country Hills Pedestrian Overpass has a 110-ft Ductal® drop-in girder, produced and installed by Lafarge’s Alberta Precast team. Spanning over 6 lanes of traffic, this 160-ft clear span pedestrian bridge now provides the two adjacent communities with an aesthetically pleasing and durable curved-linear link.

The Cat Point Creek Bridge in Virginia has five, 80-ft Ductal® girders, produced by Bayshore Concrete Products for the Virginia Depart-ment of Transportation (VDOT) and the Federal Highway Administration (FHWA). This bulb-tee girder bridge with conventional cast-in-place deck demonstrates the ability of Ductal® to provide long bridge girders (without rebar or stirrups for shear) with reduced weight and im-proved durability.

The new $5.13 million structure replaces a 70-year-old bridge. VDOT closed the old struc-ture last spring, after a routine inspection re-vealed extensive corrosion and deterioration of the steel beams. The closure resulted in a 5.5 mile detour for several months. Abernathy Con-struction Corporation of Glen Allen, VA began construction of the new two lane bridge, which is more than 800 feet in length, in the spring of 2007. They delivered the project on time and on budget.

Building on these four examples involves exten-sive, ongoing research by various universities and the FHWA. Today, there are several Duc-tal® bridge projects under construction or in the planning stages. Ductal® bridge development is currently ongoing in the states of New York, Iowa, Florida, Virginia, Georgia, and the prov-inces of Ontario and Alberta.

Innovative Ductal® bridge solutions continue to pave the way in North America with recent completion of four unique bridge projects, each validating the material’s ability to create strong, durable and cost-effective alternative solutions for low maintenance structures that are built to last.

Building Bridges

Jakway Park BridgeIowa (United States)

Hawk Lake BridgeOntario (Canada)

Why use Ductal® for bridges? • Improved durability• Ductility• Flexural strength• Superior freeze/thaw resistance• Resistance to continuous flexing across joints (from truck loads)• Reduced traffic disruption & risk during construction• Longer, thinner spans• Increased usage life• Impact & abrasion resistance• Dimensional stability• Low chloride ion diffusion• Faster construction• Reduced maintenance• Extremely low porosity


Intertitres

Acroches

tire légende

corps legende

Textes

Titre

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Listed by Unesco as part of a World Heritage site, the Pont du Diable footbridge, designed by architect Rudy Ricciotti and engineer Romain Ricciotti, constitutes a first for Europe. A 70 meter-long, muscular girder provides discretion and lightness, thanks to the exceptional prestressing resistance of Ductal®.

STRUCTURES

Pont du Diable footbridge: From utopia to reality

The choice of material to use in projects is key to fulfilling architectural and en-gineering requirements.

Two types of fibers can be used to make Ductal® products: high carbon metallic or organic, poly-vinyl alcohol (PVA) fib-ers. When choosing which fiber to use, determining factors include strength and rheology requirements, exposure to corrosive agents, desired aesthetics and exposure to human contact. Ductal® is not incompatible with rein-forcement - quite the contrary. When metallic fibers are used, Ductal® does not systematically undergo heat treat-ment, but it does stabilize the material, enabling it to achieve higher strengths faster. Additionally, the choice of mate-rial and the way it is used has an impact on the finished aesthetics, therefore prototype testing and validation is re-quired during the preparatory phases. Some projects do not leave much room for choice. For the Pont du Diable footbridge, Ductal® with metallic fib-ers (heat treated) was used in order to meet the structural requirements and the Ductal® façade and mesh panels were produced with organic fibers in order to meet aesthetic and colour re-quirements. The choice is less obvious for some other projects such as stairs, slabs on supports, shelters/roofs. where Ductal® with metallic fibers (without heat treatment) or reinforced Ductal® with organic fibers are applicable.

Whatever your project, the Ductal® team is available, to help you make the best choices. For contact information, see: www.ductal-lafarge.com

FOCUSWhich Ductal® product is right for your project?

“The paradox between high-level technological assertion and physical disappearance

assumes its full value and meaning in an exceptional

landscape.”Rudy Ricciotti


Welcoming nearly 600,000 visitors every year, the gorges de l’Hérault in the south of France, reveals stunning landscape, classified sites, historical monuments, a protected biotope and a state biological reserve. At the heart of this popular tourist attraction, the Pont du Diable footbridge accommodates up to 250,000 pe-destrians and cyclists every year. With these excessive numbers in mind, developing the landscape and restoring natural spaces were at the core of the grand site project’s design, with hight emphasis on the organization of walking trails.

As an essential element of the development project, the Pont du Diable footbridge opened in the summer of 2008, allows pedestrians to explore the area and discover its richness at an easy pace. The structure, at 70 meters long and 1.80 meters wide, is according to Romain Ricciotti “neither an arch, nor even a suspend-ed footbridge, but a simple beam set on two supports: the two banks, to cross the gorge”.

Material able to withstand very high pre-stressing “A performance that could be achieved by dividing the structure into 15 monolithical segments, cast from a single mold, which are placed on the scaffolding. No casting is carried out on site, everything was previously cast in the factory and then placed on the scaf-folding.

A material that withstands very high levels of pre-stressing

The design called for an attractive, single span, 69 m footbridge with no other bear-ings, minimal elevation and no arches or stays.

Two parallel, isostatic beams (produced with Ductal® with metallic fibers) form the railings. Ductal®, is frequently referred to as “Ultra-high performance, fiber re-inforced concrete” (UHPFRC) and with-stands very high pre-stressing levels, due to its high resistance to compression. The two bone-shaped beams are optimized to limit the impact of the structure, with an ultra-high slenderness ratio and static height of 1.80 m. A width of 1.88 m be-tween the two beams provides a usable space for pedestrians and cyclists.

The slenderness ratio of the footbridge, unlike conventional structures, requires the use of mass dampers to limit the ef-fects of vibratory coupling between the wind and the footbridge.

The colour of the concrete and its organic section (100% of the material is struc-tural) reduce the print of the bridge in the landscape. Construction was carried out by Freyssinet and Bonna Sabla, who perfectly mastered the use of UHPFRC; a material that shortens and simplifies the work, minimizes the impact on site, and improves working and safety conditions. (This 144-ton bridge was built by a team of 6 workers.)

Within these sectors, space was reserved for the cables that were tensioned to place the segments under compression (up to a tenth of a millimetre of tolerance*) thereby form-ing the beam. This ultimately produced a “flat vault”; a conventional pre-stressing technique, which is enhanced by the performances of Ductal®. Thanks to this material, it is no longer necessary to reinforce the concrete with steel as previously the case. Therefore it is possible to build a structure with a deck just 4 cm thick. The resulting visual expression is a static height of 1.80 m for a span of 70 m.”

For its designer, Rudy Ricciotti, the footbridge shows “that the difference between utopia and action is this reality of implementation. The paradox between high-level technological as-sertion and physical disappearance assumes its full value and meaning in an exceptional land-scape. It means believing in the material and what we can get it to say. And asking one’s self whether the structure’s mathematical reason-ing belongs to the person reasoning or whether it is already part of the material itself?”* A performance due to the quality of the mold and

Bonna Sabla’s precaster.

Visual expression: the priority

REHABILITATIOn

Szolyd’s team meticulously fabricated custom moulds to replicate the original columns which included intricate details in the polyurethane liners to match the mortar lines and texture of the original glazed terracotta tiles. The moulds were used to cast one inch thick skins designed to cover existing concrete substructural col-umns. Structural engineers developed a mortar free installation method for the columns using hidden mechanical fasteners. These fasteners were cast into the columns and married to fas-teners that were imbedded in the substructural columns.

Szolyd’s solution for the columns addressed not only the façade’s aesthetic requirements but also the owner’s concern about long term maintenance costs and overall durability. The columns’ color is integral, eliminating ongoing maintenance costs associated with coating.

Because of the hotel’s downtown street-level lo-cation, the building is prone to graffiti and van-dalism, therefore an anti-graffiti coating was ap-plied so that spray paint and felt markers could be easily removed with an industrial cleaner.

Ductal® cladding restores an old hotel to its original beauty

The transformation of the Hotel Rialto in Victoria, BC, Canada has marked a significant step towards the revitalization of the city’s downtown core. Built in 1911, this five-storey, Edwardian style hotel (once considered “upscale”) was formerly known as the Prince George Hotel, and the Hotel Douglas (since 1918) until its most recent makeover in 2007 and 2008.

During the course of the renovation, several other restoration pieces were needed for com-pletion of the façade construction. To meet these needs, Szolyd manufactured plinths and curbs for the base of the columns from a tra-ditional concrete mix. These were cast from custom moulds to match the original granite skirting tiles for the building.

In 2008, Szolyd successfully completed the manufacture and installation of a series of unique Ductal® architectural precast cladding elements, garnering fast appreciation from the local residents who are more than pleased to see the evolving beautification and fitting restora-tion of this former run-down, historic landmark.

www.szolyd.com

Hotel Rialtoterracotta replacement

With its proximity to City Hall, the building’s pe-riod design elements including brick cladding, terracotta columns and cornice and dentil mold-ings, established the hotel as historically signifi-cant and led to its designation as a municipal heritage site in 2005. The original façade com-prised 11 columns in two sizes, clad with white glazed terracotta tiles. Years of use and several renovations during the 1970s and 1980s left the façade unrecognizable and much of the ter-racotta damaged beyond repair.

As the owners sought options to restore the façade to its original appearance, they consulted restoration specialists from local precaster (and Ductal® sublicensee), Szolyd Development Cor-poration. Szolyd’s team recommended cladding the existing columns with Ductal® because it provided a strong, durable alternative to the dif-ficult to find and costly terracotta tile. Because of its design flexibility and superior moldability, Ductal® was ideally suited to replicate the color, texture and form of the original tilework of the columns.


TECHnOLOGY

The core of its calculation program integrates powerful non-linear calculation algorithms, taking account of the intrinsic laws of material behaviour and the effects of large deforma-tions. These features are particularly adapted to calculating Ductal® structures.

In fact, Ductal® design calculations, accord-ing to the French guidelines of SETRA* and AFGC*, require the use of a non-linear law of behaviour, that is elastoplastic in tensile state, both for Service Boundary Conditions and Final Boundary Conditions. Most of the Finite Ele-ment software on the market is based on non iterative linear elastic calculation. This type of calculation cannot be used to model the real effects of load redistribution by hyperstaticity. Yet, as its name implies, Ductal® has ductile behaviour, allowing graduated load redistribu-tion more apparent in structures with a high degree of hyperstaticity.

Furthermore, the thin layers permitted by the material require large deformation testing to take account of instability phenomena, previ-ously seen in metal construction.Sofistik lets you make this type of doubly non-linear, large deformation calculation. These large deformations, initially caused by mate-

Sofistik : How to master complexstructures in Ductal®?Sofistik is a digital calculation software that allows you to model the behaviour of complex structures. A powerful tool for architects and engineering departments wanting to initiate Ductal® structures that have not yet been utilized.

rial non linearities, are themselves sources of geometrical non linearities leading to large displacements and unstable behaviour in the neighbourhood of the rupture. You can also calibrate calculation imperfections based on the preponderant buckling modes and run cal-culations for an imperfect structure to best sim-ulate the manufacturing faults and tolerance. Aside from these possibilities for a fine assess-ment of the mode of rupture, Sofistik contains varied and integrated modules in the same platform, such as the module for calculating pre-stressed concrete structures developed with the firm VSL or “form finding” modules to calculate deformations of the 3rd order.

Based on all the above statements, a collaboration was set up between Sofistik, C&E Engineering and the Lafarge Duc-tal® team in order to develop a module designed for Ductal® in generalist Sofistik soft-ware. Over a period of two years, a series of test cases will be run to calibrate the module to a series of “standard“ cases already performed.

Integrating a law of behaviour for Ductal® into the selection of materials will be the first step in this joint development phase. To provide the best possible support for structural engineers

Punching test of a stepComparing computer simulation and live testing


in advanced calculations, training seminars will be regularly held by Lafarge with the Sofistik development teams. Whatever the engineer-ing approach, the tool however will not sub-stitute a fine understanding of the physical phenomena, which only experience and the sharing of knowledge can guarantee.

*SETRA = French authorities of civil engineering

structure design and control

*AFGC = French association of civil engineering

www.sofistik.com

Zoom

The complete Ductal® kitchen With a specialty in the production of deco-rative concrete elements, the Italian firm, Il Cantiere caused a sensation at the Milan Furniture Fair last April. Capitalizing on their expertise in countertops, II Cantiere worked in collaboration with kitchen designer Com-prex and Siemens, to produce an attractive, functional kitchen module that is entirely made of Ductal®.

“We started out with the idea of making the countertop and back of the kitchen module in Ductal®” explains Gigi Rossi, designer and co-founder of Il Cantiere. “But the technical characteristics and perform-ances of the Ductal® product urged us on to pick up the unlikely challenge of building the whole kitchen in concrete, with doors that are lighter than Corian and even lac-quered glass. Beyond this lightness, which has now been achieved, the resistance drew the attention of not only kitchen designers, but also architects and designers present at the fair.”An innovation to watch.

www.ilcantieresrl.it

DESIGn

As a specialist in high-end fire objects that burn natural plant alcohol, Climart invites top design-ers to rethink the universe of fire. The famous designers – Philippe Starck, Somnuk Thao or Ora-Ïto – have chosen the brand to display their creativity. No chimney, smokeless and dust-free, the creative possibilities of these fire objects inspire designers, especially as they can take advantage of materials like Ductal® to create veritable sculptures of light and fire. Like the creation of designer Ora-Ïto, who produced a particularly refined and elegant outdoor series, using all the potential for ductility and finish offered by Ductal®. The partnership between Cli-mart and the prototype engineering and precaster Cogitech, resulted in the design of a piece that is light and very high quality. “Specialized in develop-

ing and producing high-end pieces in limited series, we went on to imagine a shell in two parts made by compression molding and assembled with no visible joins,” explains Sylvain Quidant from Cogitech.

“The thickness of Ductal® was redefined to produce an object weighing barely 25 kg, integrating ceramic insulation to favour thermal conductivity.” A safety aspect that is important for Climart which is develop-ing a range to meet all the required standards. The company was, moreover, one of the members be-hind the French Standards project Norme Française D 35-586: “Domestic appliances for intermittent use, burning an ethanol-based fuel”, and is part of the committee responsible for drafting this NF (French standard) project. As a precursor to a booming trend in decoration, Climart pays careful attention to the plant alcohol it distributes.

www.cheminees-bio.com

Fire objects by Ora-Ïto and Climart: when design rhymes withenvironment

Taporo: the creative freedom of concrete…

Editorial team:Jean-François Batoz - Laurence Jacques - Lisa Birnie - Anne-Sophie Fenart

Editor: Philippe Billon

Credits: Photothèque Lafarge

Design/production: Agence All Write 01 53 59 83 83

Printing: Imprimerie BM

Allo Lafarge : 0 820 385 385


In Paris, Philippe Tissot has created the Taporo Workshop; a unique design studio where he and other designers can work together to create and build innovative concrete furnishings. This Work-shop has produced a wealth of original creations, essentially devoted to the many creative possibilities offered by Ductal®.

Meditation tables, futuristic libraries, decorative panels, outdoor tables combining concrete and steel... all created by the Workshop participants, are the fruit of its vocation to welcome artists and designers from different backgrounds to a perma-nent place for exchange and creation in the domain of concrete. “Modern concrete is actually a pleas-ant, silky material that is sufficient in its own right”, according to Tissot. “The undeniable advantage of ultra-high performance concretes is the gain in elasticity that is made possible due to their compo-

sition, as well as an amazing capacity to reproduce impressions.The new performances offered by Ductal® allow the crafting of exceptionally fine furniture. The lines are fluid and light. Hand polishing the surfaces pro-duces finishes ranging from mat to ultra-brilliant.” The success of this initiative also depends on Tis-sot’s own creations, on display in his gallery on the famous Boulevard Saint-Germain. Specialised in furniture, the Workshop produces stunning pieces like a curvaceous desk with invis-ible jointing. Limited series or exclusive items such as coffee tables, dining tables, fireplaces, decorative wall panels or lamps, which share the elegance of the sublimated raw material, smooth or structured textures, capturing patterns that only the properties of Ductal® will allow.

www.taporo.com


Zoom

Ductal® lights upTopos Environment, producers of furni-ture and design, is once again extend-ing the creative scope of Ductal®.

Developed as part of its Senso range, the light table was a popular feature at the “Equip’Hôtel“ (international exhi-bition for restaurants, hotels, bars etc.) held in Paris at the end of 2008.

A tabletop made with Ductal® in which Topos Environment placed a solar sen-sor, linked to an optical fiber and LEDs network . When night falls, the light ta-ble shines for around 5 hours (a 220 V or low voltage electrical system is also available for indoor use). Soft and smooth, resistant to stains, abuse and fire, weather resistant, solid yet man-ageable, extremely stable on outside floors, the light table gives free reign to the originality, imagination and senti-ments of the user. This truly opens up a new area of innovation for indoor and outdoor furniture.

www.topos-environnement.com

Rudy Ricciotti,architect

Villa NavarraProvence

P.03P.02

Ductal®,outstanding material

Rudy Ricciotti,architect

An architecture of confrontationbetween landscape and materials

DesignA material used sparingly to meet the loads

PrefabricationThe art of moulds and pouring

AssemblyA traditional journeyman’s task

03

04

08

10

13

17

Developed by Lafarge, Ductal® ultra high performance fibre reinforcedconcrete has innovative properties which pave the way for architecturaldesigns hitherto unheard of.Its special composition gives it exceptional compressive strength, six to eight times greater than normal concrete. For structural applications, the use of special metal fibres providesDuctal® with ductile properties, hence the name: with flexural strength tentimes that of standard concrete, it can undergo substantial working stresswithout shearing.Ductal® is easy to use, and provides an infinite number of newpossibilities. Its fluidity and the absence of conventional aggregates in its composition enable it to adapt to the slightest detail in the formworkand allow for the creation of extremely fine and thin forms that cannot be obtained with a traditional concrete structure. The resulting surfacesreproduce, with exceptional precision, the texture of the moulds. The surface appearance can thus adopt a range of aspects, and whenpolished, it can even imitate stone or marble, providing a remarkableaesthetic finish. Ductal® is resistant to corrosion, abrasion, pollution, bad weather orshocks, making for a life span 2 to 3 times longer than that ofconventional concrete. Ductal® is an integral part of a sustainable development approach. Its mechanical performance, combined with its durability, its aestheticqualities and its high compactness help reduce the environmental impactof construction, throughout the building's life cycle. Ductal® requires half as much material and energy and results in CO2 emissions of up to half those induced by conventional concrete. It features the thermalmass capacity of concrete which, when optimized, helps reduce energyexpenses when the building is in service.All these features make Ductal® a high performance and sustainableconstruction material capable of the most impressive of architectural feats.

DUCTAL®,OUTSTANDING MATERIAL FOR AN ARCHITECTURE OF EXCEPTION

Texts: François Lamarre. Photo credits: Philippe Ruault;Agence Ricciotti (cover, P. 08, P. 09, P. 15); Elise Sévère (P. 09, bottom). Edited by Lafarge. Design and production:External communication Lafarge;

VILLA NAVARRA

Villa NavarraRudy Ricciotti,architect Romain Ricciotti,engineer Mouloud Behloul, engineer

the building site is par excellence the heroic moment,the struggle begins at the time of ordering, with the designwork setting the scene and shaping the guiding forces. For thearchitect, it is quite literally a question of dominating matterby shaping it. The smallest architectural project, no matterwhat the scale, is thus the pretext for a conceptual joust, whichtakes on epic proportions visible in the final work. Thechallenge laid down to the laws of physics leaves its mark inthe design and the material and with a little imagination onecan sense the almost physical commitment of the designer.The Navarra project is no exception to the rule in spite of therelatively small proportions of the work. The building, halfway between a house and an art gallery, escapes mundanedomesticity through the heroic stance taken towards itslocation and its description. The order from the art dealer,Enrico Navarra, lends itself perfectly, justifying innovationand asking for a real feat.

Rudy Ricciotti has the gift of transforming all hisbuilding sites into epics. He makes each one of hisprojects into a personal struggle, into which he soon enrols all the other actors involved in the designand implementation.

If

“The intention is for the villa to be an artgallery, which can be visited by internet”, summarises RudyRicciotti, “and it will not be open to the public. It’s anabstract place, whose function is to constitute an enigma.”

P.05P.04

Rudy Ricciotti,architect- Officer of the Arts

- Chevalier of the Legion of Honour

- Laureate of the NationalArchitecture Grand Prix 2006

Projects and achievements

- The Footbridge of Peace, Seoul.

- National Choreography Centre,Aix-en-Provence.

- ITER France headquarters(International ThermonuclearExperimental Reactor),Cadarache.

- National Marine Testing andExpertise Centre, Toulon.

- University of Paris VII, reuse ofthe great mills, Paris.

VILLA NAVARRA

idden away in the hinterland of the Var coastline, thebuilding achieves its objective by nestling into the

slope so as to blend into the natural vegetation of the Provencallandscape. The desire for discretion meets here with concernfor the environment by limiting the impact of development onthe site. The principle of modesty dictates the positioning andthe form of the construction, which has a quiet profile.The platform, cleared beforehand for the construction, leavesthe rock bare and the plot of land stripped, to be plantedtomorrow with cork oaks and cypresses. As for all the privatehomes previously conceived by Rudy Ricciotti, the relationshipwith the landscape is direct and frontal, accompanied by acertain discretion, which banishes disruptive elements. Thebuilding, positioned along the contours, is by its volumessimilar to a dry stone wall. Its firm horizontality often followsthe horizon out at sea and at other times the green and undu -lating tide of the fronds of vegetation. Ricciotti’s houses standguard; sometimes they even take on a camouflaged aspect. Asfor Villa Navarra, it resembles a watchman lying on the slopeof the maquis.

The confrontational attitude is accompanied by no nonsenseforms: in this case, a simple rectangle of forty metres long byjust ten wide, encompassing a volume built on one level anddoubled by a basin in the foreground that extends out into thelandscape. “The radical treatment of the house’s geometry,”which is the architect’s signature, is masterfully interpreted inthe technical approach to the building’s construction. The VillaNavarra practically boils down to its roof: an immense visorstretching forty metres between the trees, a distinctive sign ofthe watchman hiding deep in the woods. This cantileveredsurface of 7.80 metres opens up the house to the wild Varlandscape. Only a thin line of façade gives away its hiddenpresence: an added line, blackened by coal.

P.07P.06

"The "Villa Navarra" can be summed up by its roof structure: an immense visor stretching 40 m betweenthe trees, a distinctive sign of the watcher

in the shadows."

FRONTAL ATTITUDE A simple rectangle defines a volume,established over a single level, and doubled by a basin that extends out into the landscape.

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VILLA NAVARRA

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executed it. The art dealer was clearly inviting the architect toindulge in a veritable creative act. This is how a work of art willtomorrow house other works of art, going beyond a questionof format by the nature of the questions posed and the inten-sity of the thinking. The creative spirit which took over theconstruction makes architecture the reflection of the arts andbroadens the builder’s scope, both in and calling the tune. The project, as executed, is thus almost a prototype and itsexecution a case study. Mouloud Behloul, the engineer in chargeof the Ductal® development at Lafarge, points out that “the roofwas the opportunity for all of us to think about a structureworking mainly through flexing, due to the cantilever whichtypifies it and with no pre-stressing, the engineer’s normalapproach, in order to thoroughly test the qualities of thematerial.” An approach even more unheard of and singular thanthat of the footbridge in Seoul, the architect’s first projectundertaken with Ductal®, of which the single 130 metre archnaturally only works by pressure and makes use of pre-stres-sing to reinforce its voussoirs and optimise performance. AtVilla Navarra, the 7.80 metre cantilever makes the roof one ofa kind and its execution in Ductal© is a world first.

If discretion is the order of the day and the planned use virtualvia internet, the construction itself is not at all virtual! The workis very real; it is even highly concrete and reeks of effort andapplied physicality, as the architect is wont to say in imagina-tive terms.Under his leadership, the project took on an innovative dimen-sion, which made the undertaking exciting: an exploration ofmaterials, namely ultra-high performance fibered concreteDuctal® developed by Lafarge. By concentrating on the roof,the project gave itself a structural challenge, going beyond thedimensions of the plan to take on the status of a work of art.Applying civil engineering to this scale of project is the firstachievement of the architect; the second lies in the way he

ROMAIN RICCIOTTI Structural engineer.

MOULOUD BEHLOUL Concrete engineer at Lafarge .

An architecture ofconfrontation between landscape and materials

VILLA NAVARRA

PRE-CASTED MODULES The extremity of the modules is open to add weight and make use thelight in this part with an open top.

omposed of 17 juxtaposed panels, the roof of theVilla Navarra makes full use of Ductal®’s qualities. Thematerial is used 100%, as if left to its own devices, with

no other assistance than traditional reinforcing placed at theupper part of the ribs. Even then the reinforcing is mechanicallyredundant, used in the end as a safety measure, just as thesafety net protects the performing acrobat.The roof, of optimal design and structure, makes use of a designthat faithfully follows the load lines with great economy ofmeans. “The material is placed exactly where needed in orderto be able to express itself,” enthuses Mouloud Behloul. The architect’s son, the engineer Romain Ricciotti arrived at theform through painstaking drafting, dictated by all manner ofconstraints, starting with the most pressing: getting all thematerials to the building site in the middle of the countryside.The road network is, therefore, the first factor behind the dimen-sions of the roof, composed of modular, pre-fabricated parts.

The final module is a panel measuring 9.25 m x 2.35 m, whosedesign is suitable for the spreading of the load in the plannedstructure, which is made up of a plate of a constant thicknessedged by two lateral progressive inertia ribs, higher at thesupports and becoming gradually thinner, meeting the thick-ness of the plate at the far ends. The ends have a clever opendesign to save weight and to allow the light to enter this partopened up as a porch. “The design produces an optimalmechanic, which is not without similarities to steel forms, compri-sing a web, wings or a purlin,” comments Romain Ricciotti, “andthis form is not the result of any particular design feature.” A specialist in mathematical modelling, the young civil worksengineer almost goes on the defensive about having held thepencil. “Structures behave as conceived and calculated,” pointsout Mouloud Behloul, who accepts the pre-defining of the shape,namely a plate edged by lateral ribs, “in as much as a structurenever imposes itself and is always a matter of choice,” so saysthe engineer!The decisive factors behind the size of the roof panel are, there-fore, its own weight, the allowable overload due to weather,wind resistance and heat expansion, which it is likely to sufferin a region subject to high amplitudes linked to sunshine andhigh winds. These amplitudes are all the greater, as the surfaceof the un-insulated roof is left bare, benefiting from the finishedlook and the waterproof qualities of the Ductal® panels.

“The aim to reduce the impactof the villa on the site led to the use of anultra-thin roofmade of Ductal®which comes to a thickness of3 cm at its tip.”

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C

DESIGN

A material used sparingly to meet the loads

DUCTAL®

The material was used 100% for the roof structure, making the most of all its properties.

VILLANAVARRA

THE DESIGNThe design produces optimal mechanics, which recalls the design of steel profiles.

THE LINE OF EFFORT The module is formed by a panel whose design matches the distribution of effort in the structure.

TECHNOLOGICAL REQUIREMENTS The manufacture of the metallic moulds was performed by a supplier from the aeronautical industry.

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PREFABRICATION

The art of moulds and pouring

his choice, apart from the experimentation withmaterials that it affords, corresponds to a consciouschoice of building method. Rudy Ricciotti is enthu-

siastic about the combination of a high tech product, as repre-sented by Ductal® and industrial prefabrication, with traditionalfitting without the constraints of the sophisticated processesnecessitated by pre-stressing. If the formulation of Ductal®belongs to the world of the very latest highly sophisticatedtechnology, its use is gradually becoming less dependent onlaboratory culture, becoming known for real operational perfor-mance on the bulding site. Traditional fitting gives this innova-tive product, the result of ten years of research, a shared andmass appeal, which finally allows one to foresee mass usage inthe short term. This “schizophrenic” relationship betweenproduction and fitting fuels the architect’s hope of seeing thisfamily of concretes quickly becoming a material used by masons.

The first stage in the process, prefabrication, still relieson the experimental culture necessitated by the material.The theory is already tainted by empiricism, having benefitedfrom the expertise of the precaster, namely the Bonna Sablacompany, located near Montpellier, France. The production ofthe mould and the method of pouring are determining factorsfor the production of these parts with elaborate and complexshapes, which also have a finished surface. The technologicalrequirements are satisfied by the metal moulds which areproduced by an aeronautics industry supplier. “In this way, twodifferent industrial worlds, which normally are not aware ofeach other, are brought together in the manufacturing process,”notes the architect.

THeat expansion is by far the most difficult to predict. Thehighest expansion recorded due to variations in temperaturecan be as much as 5 mm and, when the calculations give atheoretically doubled value, as much as one centimetre. Ductal®,as a new material, challenges all the usual methods of calcula-tion. The delicate lines made possible by the material mean thatthe engineer must ask himself all manner of questions neverheard of with buildings in traditional concrete, particularlyquestions about expansion and twisting. “The calculationsthemselves are ordinary” says Mouloud Behloul, “but it’s theapproach that is not, above all for concrete.” The thickness ofthe slab to resolve the problem of twisting has been measuredat 35 mm, “a sheet of paper in terms of concrete!

Originally designed for post-stressing, the panels would nothave been very different, apart from necessarily being firmlyanchored, as dictated by post-stressing. Entirely made of UHPFCDuctal® and reliant on this one type of material (except for thefixed reinforcing which was eventually placed in the ribs), thepanels lie in a more traditional fashion on two longitudinalbeams, placed 1.50 metre apart, forming a technical gallery.Supporting braces, made up of a rod inserted in a socketinjected with resin and bolted at the surface with a wing nutholding in place a load spreading plate, are placed along theback beam. For the second beam, simple neoprene cushionsform the support.

“Ductal®, as anew material,

challenges all the usualmethods of

calculation.”

VILLANAVARRA

Neither is it by chance that the next steps have something incommon with aeronautics, notably through the run-off ofliquids. The direction of the metallic fibres that make up Ductal®is not the least mysterious of the phenomena observed whenmanipulating the material, requiring a methodical and skilledapproach. The mechanical performance being dependent on thedirection of the fibres, it is essential to determine the pouringprocess which will align the needles in the direction of the flowof liquid. The extremely fine texture of these concretes, of whichthe largest particles reach only 0.5 mm, facilitates this hydraulicbehaviour, which conditions the mechanical direction of theneedles carried by the flow.

“Proportionate to the other constituent parts which makeup UHPFC’s, including silica fume, these fibres play thesame role as reinforcements in traditional concretes,” notesMouloud Behloul to explain the extraordinary resistance obtainedby these clever formulations of which certain components arekept secret. For the production of the Villa Navarra panels, themoulds were set up back to front, pouring was carried out longi-tudinally for the profiled ribs on the edges and transversally forthe plate, as witnessed by the oblong gaps retained at the ends.The checks carried out on the first prototypes showed the wellfounded basis for this method, with the fibres always correctlyaligned. “This is choreography for materials,” notes RudyRicciotti, who is in wonderment over the “huge gap that existsbetween the minuscule scale of the fibres and the 7.80 metrecantilever that the calculations allow for.”The turning out of the mould carried out next happens aftersteaming at 90 °C for a more rapid curing of the concrete. It givesa smooth and shiny surface, of which the burnishing is accen-tuated by the darker tones caused by the fines used in the formu-lation of the concrete.

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THE EXPERTISE OF THE PRE-CASTERThe pouring method is vital in obtaining the elaborate and complex forms.

“The direction of the metallic fibres used in Ductal® requires a methodical and skilled approach.”

VILLANAVARRA

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ith the on site assembly of the panels, the epicstory of the roof runs into the traditional world

of construction, its ups and downs and its constraints.The architect is in his element, caught between his fascinationfor the latest technology in materials and his ancestral attrac-tion for the building site and the men who work there.The magic of this roof with its pronounced cantilever was notimmediately obvious. Apart from the opinions sought afterbeforehand from experts in the field, in particular JacquesResplendino, the Setra engineer who compiled the standard forUHPFCs, the assembly was subject to a methodologicalapproach also involving the stone mason Ortunio. The instal-lation of these panels weighing approximately 3 tonnes eachand brought by lorry to the plot, was at times epic, “similar tothe passage of the ship over the hill in the film Fitzcaraldo byWerner Herzog,” comments the architect with hindsight. “Mutualtrust was created from one end to the other of the chain, makingthe operation a story of fellowship,” he likes to say.Lifted by a field crane, the panels were positioned on the twosupporting beams, then pushed against the preceding one bybeing slid sideways and finally propped. They are joined bymortise and tenon at the bulge in the ribs by the positioning ofa socket subsequently injected with resin. The fixture to the backbeam is achieved by the previously mentioned sunken braces,

LESS IS MOREThe precast and the work site are forgotten;the roof structure dominates the landscapeand is reflected in the water.

ASSEMBLY

A traditional journeyman’s task

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working in traction, whereas support is provided entirely by theinterior beam, equipped with neoprene.In order to avoid any tapping in the façade between these juxta-posed panels, similar to giant tiles placed edge to edge, a systemof transversal axes in the form of a steel rod anchored in thelifting points at the ends of the panels and sealed by a resin,reinforces them. A silicon joint, placed later, guarantees water-proofing of the upper part of the ribs, which are thus joined andreinforced.The old fashioned part of the procedure and the fixing by simplemetal bolts contrast with the sophisticated technology whichpreceded the development of this new type of plastic materialand the manufacturing of the panels in elaborate shapes.

It is in the ability to express these two worlds, of industryand of tradition, that the greatest sources of innovationfor Ductal® reside, as for those builders who choose to allowthis strange material to “talk”. The major work finished and the landscape growing back aroundit, there are no signs of this epic undertaking. The epic momentsof the prefabrication and the building site are forgotten, leavingthe roof to reign over the landscape and to reflect in the watersof the pond, henceforth frozen in harmony, still and as if at peace.

"Mutual trustwas created from one end to the other ofthe chain, makingthe operationa story of fellowship."

A VIRTUAL TOURThe structure is quite real; a strong materiality which exudes the effort and physics applied, as the architect puts it.

VILLANAVARRA

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Lafarge61, rue des Belles Feuilles - BP 40

75782 Paris Cedex 16 - FrancePhone: +33 1 44 34 11 11

External CommunicationsPhone: +33 1 44 34 58 30

Fax: + 33 1 44 34 12 00

www.lafarge.com

Thiais RATP Bus CenterDesigned by the architects

Emmanuel Combarel & Dominique Marrec

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Developed by Lafarge in conjunction with Rhodia and Bouygues, Ductal® concre-tes have innovative properties which lead to new and original architectural solu-tions. Ductal® is a range of fiber-reinforced, ultra-high performance concretes.It contains steel or organic fibers which give it ductility properties (this is whereits name comes from). It has high flexural strength and can be subjected tostrong forces without breaking. Ductal®’s unique composition also gives it outstanding mechanical performance, with a compressive strength six to eighttimes greater than that of traditional concrete.

Ductal® has an infinite number of architectural and structural applications. Itshigh flexibility and the lack of traditional aggregate in its composition gives Ductal®

its great casting fluidity to create highly complex and elegant simple forms suchas ultra-slimline shapes. The resulting surfaces are highly uniform and reproducethe texture of the moulds precisely. The surfaces can take on any number ofdifferent appearances and a stone or marble effect can even be achieved throughpolishing, producing an outstanding esthetic finish.

Finally, Ductal® is a sustainable material. As well as incorporating the thermal iner-tia properties of most concretes, which, if optimized, help save on energy consump-tion and so reduce greenhouse gas emissions from the building during its servicelife, Ductal® also requires less natural resources and energy to be produced, andconsequently, helps reduce CO2 emissions during its manufacturing.

1° - DUCTAL®An ultra-high performance concrete for innovative architectural structures

2° - THIAIS RATP BUS CENTER: CREATION OF THE NEW ADMINISTRATIVE BUILDING

Offices, control center and rest area housed within the same building

3° - ECDM (Paris)Dominique Marrec and Emmanuel Combarel, advocates of contextual architecture

4° - BALANCE AND UNITYConcrete-clad building, emphasizing continuum rather than rupture

5° - A DISTINCTIVE BUILDINGPhysical, conceptual and esthetic uniformity

6° - MORE THAN JUST ADDING SOULArchitectural creations perceived as “sculptures with a function”

DUCTAL®, the architects' trump card

2 3

Written by Paul Ardenne. Photos by Benoît Fougeirol; DR. A Group Lafarge publication. Conceptionand realisation: Head of external communication at Lafarge/

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This spring, the Paris transport operator RATP will be movinginto its new “Bus Center” in Thiais (France). “As one of the world's largest urban transport companies andtechnology pioneer, it is only natural that RATP's buildingsshould reflect the company's image", states Rémi Feredj, RealEstate Manager for RATP. "The Thiais building certainly meets thisrequirement. It helps to improve the site's urban landscape. Itis the pride of the hundreds of people who will be working thereand represents a sign of belonging and a symbol of what we areall about".

Based near Orly airport and Rungis wholesale food market, thisadministrative complex comprises various services on one site.As well as a secure control center which manages three hun-dred buses, the new bus center building also houses a rest areawith facilities, open round the clock, for use by the managers,service personnel and bus drivers. The building was designedby architects Emmanuel Combarel and Dominique Marrec fromthe Paris-based firm ECDM. RATP appointed its real estate subsidiary, SEDP, as project manager.

The area surrounding the new periurban-style building is clut-tered with major brand warehouses and industrial buildings,wide streets and junctions. ECDM's challenge was to reconcilefunctionality with integration, and design a relay-type buildingwhich blends into the scenery while, at the same time, forminga modern and attractive focal point. The architects plumped for

The building looks as though it is rising outof the road or growing out of and fusingwith the landscape of unbroken minerality.This effect is achieved by covering the entire building and a large tarmac stripsurrounding it in Ductal®.

THE RELAY-TYPE BUS CENTER: It blends into the scenery, while, at the same time, forming an attractivefocal point.

FLUID CASTING: The building's entire surface is covered with concrete into which a 3D pattern has been molded.

spatial continuity. Shaped like an elevated plateau, the buildinglooks as though it is rising out of the road or growing out of, andfusing with, a landscape of unbroken minerality.This effect is achieved by covering the entire building and a largetarmac strip surrounding it in Ductal®, which has a strong mine-ral homogeneity. This elegant concrete “skin” runs along the edgeof the building before rising up so that the building (roof inclu-ded) and road merge into a single coherent structure - bestowingthe new Thiais Bus Center building with its unique identity.

Thiais RATP Bus Center: creation of the new administrative building

6

On site:Dominique Marrec and Léopold Lombard, Lafarge Director of architectural relations, at the RATP Bus Center building site.

ECDM (Paris)

7

Other major projects by ECDM currently underway include:- the Tomi Ungerer Center in Strasbourg- a 9,000 m2 student residence for Espacil Habitat in Epinay- a 6,000 m2 development for the OPAC social housing office in Paris- a 10,000 m2 housing development for Nexity Appolonia in Rennes- a 10,000 m2 office, housing and retail complex, Lyon Confluence, for ING and Atemi, in Lyon- a 5,000 m2 housing development for ING in Aubervilliers and Metz- a 6,000 m2 office and retail complex for ING and Crédit Agricole in Evry

Emmanuel Combarel:Meeting the two-fold chal-lenge of respecting strict specifications while experi-menting with an original new material.

DominiqueMarrec:

Offering simplearchitecture with

rigorous logic and without

preconceptions,nostalgia or

stylistic concerns.

The designers of the new ThiaisRATP Bus Center building are Emmanuel Combarel and DominiqueMarrec, founders of ECDM (Paris), set up in 1993. Both are ardentsupporters of contextual architecture, taking structure, restric-tions linked to function and the socio-cultural concerns of the sur-roundings into account. ECDM's style combines light, cohesionand æsthetics, and effective simplicity is also a priority. "Onedominant characteristic can be found in the firm's work, as expres-sed by Marrec and Combarel themselves. It is the desire to offersimple architecture with rigorous logic and without preconcep-tions, nostalgia or stylistic concerns."

ECDM is behind many constructions, such as the Espacil Habitatstudent residence in Argenteuil, awarded the "Équerre d’Argent" in2003, and La Tourelle school sports complex in Sarcelles (2005),where an elegant shelter now runs the full length of the sports field.This building provides an outstanding example of ambient lightingtechnology. Other projects include the HQE (French environmentalquality standard) residence in Rue Louis Blanc (2006) for the Parishousing authority RIVP, built over a ground-floor landscaped carpark and characterized by its roadside backlit façade.Designing the Thiais Bus Center provided ECDM with the perfectopportunity to express its practical and reflective approach to archi-tecture. The challenge was two-fold. On the one hand, it was requi-red to meet strict specifications which included housing monitoring,management, reception, meeting and relaxation facilities on the samesite. And on the other hand, it was required to experiment with newphysical and sensitive relationships to materials, including the ultra-high performance concrete Ductal®. In the case of the Thiais pro-ject, Ductal® is the architects' trump card, used as cladding to coverthe building and as a physical, æsthetic element to merge the ground,walls and underside of the building into one.

Balance and unity

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When working in the actual context, Emmanuel Combarel andDominique Marrec never have a preconceived idea of what thefinished building will actually look like. After a lengthy obser-vation and survey phase which generally involves consultingfuture users, the architects designed an administrative unit whichis both ambivalent and suggestive, organically emphasizing continuum rather than rupture.“Our aim was to focus on the site's mineral nature and design abuilding that merged with and grew out of the road”, saidDominique Marrec. Built next to the old Bus Center and coachdepot – both typical examples of industrial architecture – thenew building supplements, and yet forms part of, the existingsite, its cube-like form rising up in relation to the surroundings.The new Bus Center is characterized by the vast extent of concretesurrounding the administrative area and covering the adjacentroad which welcomes the constant fleet of buses. The architectswanted to extend the road into the building to give the impres-sion that it had suddenly emerged from the ground like a beau-tifully risen cake. The idea of designing a “skin”-type coveringfor the surrounding area and the building emerged quitenaturally. This skin “creates the impression that the flow

CONTINUITY: A structure in phase with the surrounding industrial buildings.

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of traffic and the building are blurred together, endowingthe site with a powerful visual density”.

This skin looks like the world-famous pattern on a piece of Lego,except that it is enlarged and reproduced ad infinitum. It is consis-tently gray in color and covers the ground around the buildingtogether with its walls and roof. Made from tinted Ductal®, it isattached as cladding to the building itself and laid flat around thebase. In addition, this pattern of regularly repeated studs meetsthe specification requirements for an anti-slip surface. It is a per-fect blend of effect and function. The ease with which Ductal®can be molded further enhances the æsthetic effect. The topedges of the building are beautifully rounded without the sligh-test hint of aggression. There is no facadism and no front or backto this building whose entire structure exemplifies unity, fromits design through to its style.

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The building's skin looks like the world-famous pattern on a piece of Lego, except that it is enlarged and reproduced ad infinitum.

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Full of contrasts:Bright colors, gray concrete and wide openings punctuatethe building's surface.

DUCTILITY: The use of Ductal® concretefacilitated the production of curved “Lego”-like slabs.

A distinctive buildingThe new Thiais Bus Center is characterized by its rare physical,conceptual and æsthetic uniformity. Clad in its Ductal® apparel, thebuilding resembles a model in a skin-tight dress. The openings in this monolithic-type block look like they were cutout of the building after it was built with a giant Stanley knife. Butthis apparent radical quality is only skin deep. In fact, grace andelegance is evident throughout this building which invites you toenter and wander along its light and airy passageways, leadingdirectly through the building and out again to the other side.The different color schemes used to distinguish the various indoorareas together with the spacious offices, generous lighting andattractive indoor patio area, bathed in a pool of light, all bear wit-ness to this elegance which makes the building pleasing to the eyeand a comfortable place to work in.

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The colors used are a physical reproduction of the equally loud colors displayed on the shop signs and billboards in the nearby shopping district.

BRIGHT INTERIOR:The tinted and partially frosted windows create light effects.

Even the reflective structural glazing conveys a sense ofelegance, with its tinted or partially frosted glass creatingmultiple reflections and mirror-like effects.

Independently of its administrative functions, the new Thiais BusCenter is intended to represent a miniature version of the sur-rounding environment. The openings are decorated, on the outside,in four different colors (blue, green, yellow and orange), contras-ting sharply with the gray concrete. This is no decorative fancybut rather a deliberate decision to use minimalist polychromewhich has a strong impact and again stems from the desire forsymbolic symbiosis. These colors have been carefully chosen andare a physical reproduction of the equally loud colors displayedon the shop signs and billboards in the nearby shopping district:“We have reused the primary, rather basic colors found in the sur-rounding area”, said the architects. This remarkable building issure to elicit two responses. Firstly, it catches the eye, its higharchitectural quality and bombastic appearance naturally arou-sing curiosity. And secondly, it generates discussion. Yet, this newbuilding is far from an example of radical autonomy and is no UFOeither, despite its unusual characteristics.This building is neither provocative nor out of touch with reality.But nor does it bow down to “poor quality” urbanity – a commoncharacteristic of the neighboring buildings. ECDM's building isboth divergent and convergent. It forms part of the local area while,at the same time, adding something to it.

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More than just adding soul

TRANSPARENCY: More than an example of esthetic excellence, the Bus Center is designedfor purpose, as its well thought-out interior design testifies.

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The patio area and many openings generously bathe the building in a pool of light.

Despite the fact that Thiais' unusual new Bus Center building is setin an environment filled with ultra-functional, low-cost buildingswith very little architectural symbolism, it is not provocative ordefiant. Its cube-like form calls to mind the warehouse-type outletsin the nearby shopping district. Its low height (R + 1) is similarto the horizontal buildings in the surrounding area. On the top ofthe building, the Ductal® façade rises skyward, ensuring visualcontinuity between the surrounding area and the building itself, enhancing, rather than diminishing, this extremely graphic attempt at insertion. The building is set firmly in context and givespriority to functionality of use.

Above all else, Emmanuel Combarel and Dominique Marrechave designed the building specifically for purpose as the

well thought-out interior design testifies. The Thiais RATP BusCenter is, nonetheless, a quite definite architectural gesture orsignature. Everything about this building is distinctive. It can-not be compared to any other building or considered an imita-tion of any existing structure. “It's a question of refusing absolute architecture”, say Marrec andCombarel, “and focusing on adapting the building to its surroun-dings”. The architects' intelligence is reflected in their work whichis devoid of all prejudice and refuses to conform to any rules.

For example, contrary to expectations, their aim in using Ductal®as a layer of skin is not to flaunt the concrete's exceptional phy-sical qualities, but rather, in accordance with an original decora-tive perspective, to highlight its power to seduce, its visual poten-tial and the unusual elegance of its mineral quality. This propen-sity to humanize a supposedly “hard” material brings to mindthe work of architect Marcel Breuer, at odds with elementaryfunctionalism. When designing buildings, this great master ofconcrete architecture liked to think of them as “sculptures witha function”.In recent decades, architecture's "sculptural evolution" has pla-ced its faith in sizeable proportions. The familiar, often disappoin-

1918

HARMONY:Ductal® creates the perfectunion between æsthetics and functionality with an elegant yet non-slip design.

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An incomparably handsome appearance is combined with precisely calibrated functionality. Here, poetry merges with purpose in keeping with a complex way of thinking.

ting result of this approach is that free form takes precedenceover function and its specific layout requirements. In its ownlively but non-aggressive way, the new Thiais Bus Center buildingprovides the occasion for revival. Its incomparably handsomeappearance is combined with its precisely calibrated functio-nality. Here, poetry merges with purpose in keeping with a com-plex way of thinking which combines the architect's quest forpure creation with the essential requirement for architecturalefficiency. So, more than just adding soul, it's all about designinga building which is just right.

Group Lafarge61 rue des Belles Feuilles, BP 40,

75782 Paris Cedex 16, France

External Communications Dept.Phone: +33 1 44 34 58 30

Fax: +33 1 44 34 12 00www.lafarge.com

Ductal

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